Roads, rail and utilities

Higgins proudly holds maintenance contracts managing state highways as well as urban and rural roads for central and local government authorities.

Using the latest technology we monitor our network assets in real time for strong whole of life asset planning and strong client collaboration.

Our asset management teams look after all aspects of road maintenance from ‘fenceline to fenceline’ to ensure safe and efficient road networks. That means we’re doing work from cutting grass, clearing culverts and filling potholes, right through to resurfacing and everything in between.

The Rangiuru Business Park is majority-owned by Quayside Properties Ltd and is the largest greenfield consented industrial zone in the Bay of Plenty, comprising 148 hectares to be developed over four stages. 

Higgins is responsible for the motorway interchange project, which is a $60M, 35-hectare diamond interchange, and part of stage one Park works.  It will provide direct entry to the Business Park from the Tauranga Eastern Link Toll Road (TEL TR), and connects future residential developments in the east, to the Business Park in the west.

Higgins was awarded this project in October 2022 and work got underway in November, with the completion due at the end of 2024.

A shared use path for walking and cycling will be built along SH75 between Little River and Cooptown. The 1.3km path would provide a safer option for active transport in the area.  Cyclists will be able to safely ride off the State Highway while travelling from the Little River Trail to the cycle trail on Puaha Road.

The shared use path will be delivered in two stages, the first stage is from Church Road to Puaha Road.

Higgins is responsible for the physical works in the first stage which include

• site clearance
• path construction
• road safety barrier
• timber boardwalk bridge
• culvert extensions
• signage and marking

Higgins was awarded this project in February 2024. The first stage is to be completed in June 2024.

The SH2 Masterton to Carterton Safety Improvement Project creates three new roundabouts – the Ngaumutawa roundabout just south of Masterton and the Norfolk and Wiltons roundabouts south of the Waingawa bridge. It also included a safe turnaround facility just north of Carterton, areas of road widening, and the installation of approximately 5.7km of median wire rope barriers. 

The overall project spans from the Ngaumutawa Road/SH2 intersection, also known as the 'heavy traffic bypass' just south of Masterton, through to just north of Carterton.

Due to the traffic volumes on State Highway 2, the project initially planned to detour traffic via Hughes Lane and be complete by the end of August 2023. The detour was rejected by local councils, so we changed to a 24-hour operation. Less intrusive works were during daytime, while works requiring stop/go traffic management performed during nightshifts. 

Most preliminary works were completed between April and July 2022, and the main construction work started during August 2022 with the construction of the Wiltons roundabout, followed by the construction of the Norfolk and Ngaumutawa roundabouts.  Construction of the roundabouts was carried out at the same time as the turnaround facility, road widening works and the installation of the median wire rope barriers. The project was completed in early September 2023, only three days later than the original date despite the design changes needed to avoid the Hughes Lane detour. 

Final pavement work is ongoing through November and December 2023 to ensure all the finishing works are completed in warmer months.

This project was the final major piece of SH4 restoration work following major flooding in the Whanganui region in 2015. It saw us relocate a section of the state highway away from where a slip occurred into the Mangawhero River.

The surrounding area has significance to Mana Whenua, so we liaised with three iwi representatives before and during construction, to make sure remediation was done sensitively.

The team also placed a lot of importance on protecting the environment. The site had four sediment retention ponds with other decanting earth bunds, as well as a lot of silt fencing to control site run-off. With the site bordered by drains, streams and rivers we had little room for error.

A further challenge was that the road was being used by commuters while repairs were underway. We established a smart traffic light at each end of the construction site for the duration of the project with one lane closure being implemented for the majority of work. No major traffic incidents occurred during the project.

The Pūhoi to Warkworth project extended the four-lane Northern Motorway (SH1) 18.5km from the Johnstones Hill tunnels to just north of Warkworth.

It is the first stage of the Ara Tūhono – Pūhoi to Wellsford Road of National Significance. By delivering a more efficient, resilient and safer connection between Pūhoi and Warkworth, the new motorway will improve journey times (especially during peak holiday periods and weekends) and freight efficiency, driving regional economic growth.

Under a PPP contract, the Northern Express Group (NX2) financed, designed, constructed, managed and will maintain the Pūhoi to Warkworth motorway for 25 years following the construction period.  After the 25-year period, NX2 will return the highway to the project’s client, the Waka Kotahi NZ Transport Agency.

NX2 is made up of companies with considerable experience in the design, construction, finance, maintenance and management of key infrastructure projects in New Zealand and overseas. NX2’s equity investors are the Accident Compensation Corporation and Public Infrastructure Partners II LP (managed by Morrison & Co PIP Limited), Acciona Concesiones and Fletcher Building.

Construction on the new motorway started in October 2016.

Design & Construct Phase – Five years with the new motorway opening in 2023. Constructors are Fletcher Construction / Acciona Infrastructure JV. Higgins was contracted to provide road construction and paving services.

Asset Management & Maintenance Phase – 25 years. Higgins and Acciona (working together as P2W Services) have the 25-year maintenance contract. They are the first team in NZ to receive the ISO 55001 Asset Management certification on a road maintenance contract. Taking an active approach to lifecycle asset management, ISO 55001 Asset Management certification helps the team manage the processes and risks in the maintenance of the assets on the motorway.

The stretch of State Highway 35 between Ōpōtiki and Te Kaha collapsed due to severe rain events during mid-July 2022,, isolating the population of approximately 10,000 on the East Coast from crucial food supplies and emergency services.

Higgins quickly gathered a competent team comprised of local suppliers and subcontractors on an emergency basis. Blessed with karakia, the Higgins-led team worked tirelessly to reinstate the road within just three days, to reconnect the communities with essential services, and five days to open a single-lane road for 24-7 access for the public.

In delivering the permanent repair of the embankment on the Motu River and damaged road, Higgins also delivered broader outcomes, particularly in contributing to the local economy, reducing carbon footprint and waste, upskilling local subcontractors as well as engaging with Te Whānau-ā-Apanui (local iwi).

Higgins delivers regular work for Auckland Transport, and recently this included construction of a Park and Ride facility at 80 Great North Road, Warkworth.

This transport hub included construction of a carpark, two toilet blocks, signalised pedestrian crossing, bus stops on State Highway 1 directly outside the park and ride site and footpath connections, lighting, CCTV installations, two raised pedestrian crossings, and a rain garden with a timber walkway, line marking and signage.

To minimise the impact on surrounding stakeholders and road users, we worked closely with utility providers, and the heavy haulage industry and all the works on SH1 were done at night.

The ‘Golden Triangle’ between Auckland, Waikato and the Western Bay of Plenty is home to some of our largest industries, including dairy, forestry and tourism. These major regional economies require efficient transport networks to carry goods, people and freight between cities, ports and international markets. The faster freight, tourists and commuters can travel between these centres, the more our economy will grow – and that’s good for all New Zealanders.

The four-lane Waikato Expressway Hamilton section reduces travel time between Tirau and Auckland by 35 minutes, while improving safety. The Transport Agency has been delivering the Waikato Expressway as a package of projects over the last fifteen years.

The Hamilton section is the largest roading project ever undertaken in the Waikato, connecting to the Ngaruawahia section of the Expressway (completed by Fletcher Construction in 2013) in the north and the existing Tamahere section in the south.

The 21.8km expressway project involved four million cubic metres of earthworks, 17 bridges, five major intersections and extensive local road crossings. Building the mega project required more than 28,000 cubic metres of concrete, 212km road markings and 126km of fencing, 1.3 million tonnes of aggregate and up to 700,000 square metres of OGPA road surfacing.

Higgins was responsible for delivering around 25% of the project scope. The team provided specialist technical and contractor input; construction of the pavement and surfacing for the 21.8km section, plus approximately 6km of local road upgrades/new construction; undertake all traffic management and oversee all traffic services and utilities works.

With a number of areas of cultural significance along the alignment, the alliance worked closely with Waikato-Tainui on environmental and waahi tapu protection, archaeological interests, work in the gullies and creating training and employment opportunities.

Carparks such as these are regular jobs delivered by Higgins. The upgrade of the Phyllis Reserve Carpark included demolition of the existing carpark and then the construction of the new carpark in a different location so the sports fields can be upgraded at a later date. Works included reinforced concrete pavements, asbestos removal, subsoils and kerbs, footpaths, speed table construction, and the installation of an Exeloo toilet block including services.

We worked collaboratively with the Metro Mt Albert football and softball clubs, planning our works around their events, as well as covid lockdowns and design changes to deliver this new community facility.

As part of the work we installed the innovative stand-alone underground jellyfish stormwater filter system. The filter mimics jellyfish by filtering stormwater through membranes. Even when there is heavy storm-water run-off, the filter can catch pollutants including litter, oil, debris, chemicals as well as tiny silt-sized particles.

This Waka Kotahi project upgraded the existing vehicle compliance testing station at Glasnevin in Canterbury as part of the Weigh Right Programme (WRP) that supports improvements to the policing of overweight vehicles.

The project scope included site clearance, minor earthworks, the installation of a new 50m-long concrete weigh bridge, extension of the existing compliance building, construction of a vehicle testing shed, drainage, power and telecommunication services, fencing, road and footpath construction and landscaping.

Our team worked to tight design tolerances, accommodated multiple design changes and worked collaboratively with the Waka Kotahi, designers, subcontractor, the trucking industry and the NZ Police to deliver this first future proofed facility with minimal disruption. 

The safety improvements on Dyers Pass Road were designed to reduce the risk of driver error resulting in death or serious injury, by installing approximately 3km of guardrail in high-risk locations. 

Dyers Pass Road links Christchurch city and Lyttelton Harbour over the Port Hills. The 5.9km route comprises a narrow two-lane road with very narrow shoulders on a winding alignment at steep grades, with a busy mountain bike track below it. The route has high crash rate with high injury severity due to the terrain. There is no nearby alternative route.

Before this project, side barriers were already in place on 23% of the length of Dyers Pass Road, yet there had still been six deaths and seven serious injuries on the road in the previous five years. Five of those crashes could have been prevented with side barriers, motorcycle under-runs and wider shoulders.

Our work involved milling out the road shoulder to remove overhanging rocks and constructing a retaining wall system to help support and widen the road where the barrier would be installed. We also sealed the newly created road shoulder, pouring channel to manage drainage, and installing a culvert at Cashmere Stream to address a stormwater issue.

There were nine sites in total over the 5.9kms, six on the city side of the Port Hills between Sign of the Takahe and Sign of the Kiwi café, and three over the hills towards Governors Bay.

Unexpectedly soft soil conditions allowed us to innovate by using a NZ manufactured retaining system that meant we could build faster and more safely, and keep one lane open for traffic.

In 2016, a 7.8 magnitude earthquake shook Kaikoura, causing major damage to road and rail networks. Higgins was a member of the alliance formed to repair the links, known as the North Canterbury Transport Infrastructure Recovery (NCTIR). Other members included Waka Kotahi, KiwiRail, Fulton Hogan, Downer and HEB Construction.
 
Most of the earthquake damage was on a section of coastline approximately 30km north and 30km south of Kaikōura. The earthquake caused more than 30 major slips that covered the road and rail network. Approximately 1 million cubic metres of material had to be moved. Multiple road and rail bridges were damaged by the quake and 24 tunnels were damaged. The estimated cost of the repair was $1.25 billion. 
 
With considerable grit and determination, the Alliance team met all of their targeted milestones to date and received industry acclaim for their ability to solve problems, work collaboratively in an expert way to achieve the mammoth logistical challenges and targets. 
 
The NCTIR project was recognised for project delivery excellence by both industry and the community with two significant awards. The alliance was named as the winner of the Institution of Civil Engineers (ICE) 2018 People’s Choice Award, beating projects from around the globe. This is an award that requires public voting and demonstrates the significance of the project to the lives of New Zealanders. 
 
The NCTIR project also received the prestigious Rail Technical Society of Australasia’s Biennial Project Award, for reopening the Main North Rail Line between Blenheim and Christchurch just nine months after the 7.8 magnitude Kaikōura earthquake. The judging panel described the Main North Line earthquake recovery project as an “Inspiring example of how railway people respond energetically and successfully to the most severe challenges.” 

This project in Horotiu, Hamilton involved the construction and extension of Gateway Drive from Evolution Drive to Lot 16 via a 120m long, multi-span road bridge over the North Island Main Trunk Railway (NIMTR).

Higgins delivered earthworks, embankment fills, ground improvement, mechanically stabilised earth (MSE) block retaining walls, pavement construction, three waters networks, utility ducting, footpaths, landscaping and large scale environmental controls that included the upgrade of a wetlands area for stormwater retention.

The focal point of the project was the construction of the multi-span bridge over the KiwiRail NIMTR, while the rail line was operational. The entire bridge construction, including the pile foundations, was delivered by Fletcher Construction companies.

This section formed part of a much larger construction project that includes the development of a future industrial and inland port area with 1km of new roads and all local infrastructure designed to support multiple business facilities.

Due to close proximity of the site to a waterway, significant environmental controls were built and maintained for the life of the project.

The Lakes Development, Tauranga is a 254ha green-field mixed residential and commercial development that was completed in three stages over 13 contracts.

Higgins managed the earthworks, drainage, roading, surfaces, utilities, streetscape, landscaping, playground construction, and commercial complex from Stage 2 to facilitate roading, carpark, reserves, accessways, footpaths and other amenities associated with this development project.

Te Ara Kahikatea was the largest roading project in Hawke’s Bay since the Napier-Hastings expressway built in 2002. The objective of the 3.5km road was to enhance and improve the safety and efficiency of the transport network across the region.

Scope of works involved building two roundabouts and a 2.85km connecting road between them including:

• Complex traffic management to keep both SH2 and Pakowhai Road functioning

• Diversion and relocations of gas, 3 waters, electricity and telecommunications

• Environmental controls, including protection of the nearby Karamu Stream.

The cost of the road was $25.2m, and completed within budget. A contributing factor to this budget was Higgins pavement construction. In partnership with the Engineer and HDC, a thorough review of pavement and asphalt make up was undertaken immediately following tender award. This highlighted further opportunities for Higgins to provide more value engineering to HDC which provided increased pavement and surfacing life, reduced whole of life costs and improved value for money. 

This project won two industry awards in 2019. The first was the IPWEA Award in the category for projects over $5m, and the second was the CCNZ Award in the category for projects $5m - $20m.

Officially opened in September 2018, the Kuaka Gateway was designed to improve safety at one of the country’s most dangerous intersections (SH2-SH2B), unlock economic growth and create an iconic northern gateway for Napier and the Heretaunga Plains.

In 2016, Waka Kotahi NZ Transport Agency (NZTA) allocated funding to design and construct an improved intersection and access to the Napier Airport. In April 2017, Higgins started construction. The project's major challenges included a very demanding timeframe as well as an extremely high-profile and a sensitive environmental site location.

Key project objectives involved safety and environmental outcomes. The design was the result of close collaboration between NZTA and its partners, the Napier City Council, Hawke’s Bay Airport, Māna Ahuriri Trust and Ngāti Kahungunu. Partners also included a design and consenting team led by WSP Opus and including Stantec, GHD, Beca, local artist Jacob Scott, and wildlife specialist Tony Billing.

There was a deliberate best-practice approach to environmental planning, engineering and landscape design, built-in Te Aranga  principles, and an outcomes-based approach to stakeholder engagement. This ensured the  project demonstrated how major infrastructure projects can be designed and delivered with net-positive impacts, even within the most sensitive sites.

The project delivered on its project objectives and was completed some weeks ahead of schedule. A collaborative, holistic view to problem-solving; and strong stakeholder engagement transformed a traffic  blackspot into a safer intersection and an admired environmental outcome for the community.

The main works involved constructing a new, at-grade roundabout at the Watchman Road, at Meeanee Quay and SH2 Intersection, upgrading the Watchman Road Causeway and installing upgraded infrastructure including a cycleway and utility services.

The Watchman Road causeway bisects the Ahuriri Estuary located within the Westshore Wildlife Reserve, a delicate natural habitat that is classified as a wetland of national and ecological significance. The road was widened and strengthened to form the community’s main road to Napier Airport.

This part of the Tasman Great Taste Trail is 5.6 kms in length and winds its way from the Norris Gully recreation area southwards through to the Motueka River Bridge at Kohatu alongside State Highway 6.

The trail follows along the edge of Nelson Forest land and travels across the Norris Gully stream under the state highway before crossing a number of bridges, including one measuring 18 metres, under the cover of the forest.

Construction began in 2018 after government funding was approved following two years of planning and fundraising by the Tasman Cycle Trails Trust.

During the construction the Higgins team on the project worked closely with land owners and the Cycle Trail Trust and the council to find solutions around track location and positioning. Other challenges included changing out electric fencing around horse paddocks and dealing with the main upper south island Chorus fibre and feeds that run directly under parts of the cycleway. The Higgins team also had to ensure they did not adversely impact road-users while constructing the trail, kept staff safe at all times and cared for the streams and environment around the works areas.

Despite the complexities Higgins finished ahead of schedule to deliver a cycleway that the local community can be proud of. The productivities have been high due to strong planning and co-operation and ownership across the Higgins crews and sub-contractors. The local Higgins crew also came up with a way to produce a great result at a cost-saving to the community by using a paver laying machine to construct the entire path rather than the traditional truck and digger method of laying the aggregate.

Ports of Auckland Ltd (POAL) contracted Higgins as the head contractor on Stage 1-3 of the new terminal pavement adjacent to the Fergusson Wharf. The project was supported by Brian Perry Civil to deliver the structural concrete, concrete pavement and utilities scope. 

Stage 1 involved cut mudcrete to subgrade, construction of 300mm of lean mix concrete with 175mm of asphalt in two layers covering a 10,000m2 area. The team also constructed 240 lineal metres of ACO slot drains and stormwater chambers.

Stage 2 was same scope as stage 1 over an area of 7500 m2 and was commenced at the beginning of February and completed start of May.

Stage 3 included milling AC and CTB to sub grade level (100mm to 475mm deep), removing this from site and then constructing 300mm lean mix and 175mm AC. Storm water drainage and ACO drains are involved and some electrical conduits. Stage 3 is due for completion mid August.

SH20A is the primary route to and from Auckland Airport and forms a strategic link between the Western Ring Route (SH20 and SH16), the Airport Business District and the greater Auckland area. By upgrading SH20A from a motorway to an expressway, the SH20A to Airport project provided a safer, more direct route to Auckland Airport and addressed long-standing congestion problems. There are now better connections to ports and industrial areas that improve freight efficiency to help support economic growth.

The project enables Aucklanders to fully-realise the benefits of the development of the Western Ring Road, taking travelers to-and-from the airport, along SH20A, SH20 through the Waterview Connection, SH16 and SH18.

The cornerstone of the project is a 400m long, 12m-wide trench that lowers SH20A beneath Kirkbride Road, separating local and airport traffic. A trench over the alternative flyover ensured the Mangere community remained connected – a large structure would have visually severed the community in half.

We delivered the project as a member the MHX Kirkbride Alliance alongside the Waka Kotahi NZ Transport Agency, and Beca. The Alliance is the same, high-performing team that delivered the SH20 Manukau Harbour Crossing Project in 2010, which won the Australasian Alliance Project of the Year.

Higgins helped Fiji improve their international gateway through the Fiji Roads Authority N2 contract.

The contract involved a four-lane construction along the Queens Road in Nadi. The previous road was a heavily-trafficked route servicing about 15,000 vehicles per day. The new road has improved travel times and relieved traffic congestion for both visitors and the local community. Other improvements included better pedestrian footpaths, improved street lighting, and upgraded transport service facilities such as new bus stops.

The upgrade was designed to improve the traffic flow using a combination of measures, including road-widening and levelling, and improvements to intersections, roundabouts and traffic lights.

Higgins was the head contractor for this corridor improvement project. 

The Te Atatu corridor improvement project have helped boost the efficiency and safety of one of West Auckland's busiest roads. An average of 38,000 vehicles a day use Te Atatu Road to get on or off the Northwestern Motorway (SH16). This makes it one of the busiest roads in West Auckland and congestion is a problem. The area traditionally also has a high incidence of accidents, some resulting in serious injuries.

The upgraded area is approximately 1.4km long and covers Te Atatu Road, from Wakeling Avenue to the Northwestern Motorway interchange (on- and off-ramps), Edmonton Road from School Road to the Te Atatu Road intersection, and for varying distances along side streets.

Construction was carried out in stages to reduce the impact on traffic congestion during peak hours and minimise inconvenience to residents.

Higgins Auckland was awarded the contract to reconstruct McKenzie Road in Mangere, South Auckland. The contract was won on the back of the Higgins road rehabilitation and paving expertise, and skilled management of stakeholders on an important arterial road that serves as the local connection between SH20 to the airport.  Higgins delivered full pavement reconstruction, including kerb and channels, driveways, footpaths and the rebuild of the road carriageway.   The project team formed a partnership with local Mangere College to mentor pupils in the civil trades and bring local talent in to the project delivery team.

The Rangiriri section is an integral part of the Waikato Expressway Road of National Significance, connecting Auckland to the agricultural and business centres of Waikato and Bay of Plenty. Beginning at the southern end of the Longswamp section, it runs for 4.8km and joins the existing highway south of Rangiriri township.

The new section aims to improve connectivity from Auckland to Huntly and further south, connect the Longswamp and Ohinewai sections of the Expressway, improve safety, particularly for those using the Rangiriri and Te Kauwhata intersections and provide improved connections for the community.

We delivered 4.8km of four lane motorway, an interchange at the intersection of SH1 and Te Kauwhata Road and another at Rangiriri, involving 1.6 million cubic metres of earthworks. 

Mackays to Peka Peka Expressway is a key section in the 110km Wellington Northern Corridor (WNC), a road of national significance, providing a more direct route between Levin and Wellington Airport.

The 18km Mackays to Peka Peka section is a four-lane expressway through Paraparaumu and Waikanae, separating local and highway traffic and creating safer and shorter trips to and through the Kāpiti Coast. Along with Peka Peka to Ōtaki to the north, it makes up the ‘Kāpiti Expressway’ and links to the south with the Transmission Gully project.

We delivered the Mackays to Peka Peka Expressway project as part of an alliance alongside Beca, Higgins and the NZ Transport Agency supported by Goodmans Contractors, Incite and Boffa Miskell.

Our work included 16km of new four lane motorway, major upgrading of 2km of highway, 18 new bridges (including a new crossing over the Waikanae River), 3.5 million m³ of earthworks, 16km shared pathway for pedestrians, cyclists and horses, connections to local roads at Poplar Avenue (Raumati), Kāpiti Road (Paraparaumu), Te Moana Road (Waikanae) and Peka Peka Road. The work also covered safety improvements on many local roads in the vicinity of the Expressway and environmental protection and enhancement including 140 hectares of new planting and landscaping, creation of 9.5 hectares of new or restored wetlands and 1.4 million locally eco sourced plants.

Higgins provided civil construction input and services related to drainage, pavement construction, surfacing and traffic management. 

In this project, Higgins built a new overbridge designed to improve road user safety and travel times. 
 
The existing overbridge’s location meant the road beneath had a poor layout and was a dangerous area for motorists. The overbridge was also not up to earthquake standards, and was too narrow for a state highway. 
 
Starting in 2013, the project hit one of its major milestones in winter 2014 with the completion of the multiplate culvert over the main south trunk rail line. The culvert was completed one week ahead of the scheduled program and without any interference to train time schedules. Taking 15 weeks to complete, the culvert consists of 54 metres of multiplate (200 plates) held together with over 7700 bolts. 
 
Higgins Nelson and Blenheim crews combined to complete the next big portion of work involving simultaneous works to backfill over the multi-plate arch and the keystone retaining walls. 

The Hawke's Bay Regional Sports Park International Hockey facility is New Zealand’s first and only Tier 1 Hockey facility.

Higgins designed many aspects of this park to ensure it met the standards of international teams and broadcasters, and delivered the project on time within a compressed 20-week  timeframe before the first International Festival of Hockey in April 2014.

Higgins Role:

• Re-design of the international pitch to allow for flatter grades and porous pavement.
• Excavated and constructed hard stands from greenfields for the turf foundations.
• Installation of subsurface drains in the porous turf.
• Design of the international pitch lighting for broadcasting to ensure Lux was acceptable for international HD Broadcast.
• Construction of concrete flood light foundations up to 5 metres deep by tremmying.
• Design and construction of viewing tower out of modified shipping containers including fibre optics and power for network connections to allow immediate play back to coaches and players in the dug outs.
• Construction of players dug outs.
• Construction of concourse, footpaths and associated amenities.

The Hawkes Bay Sports Park Hockey Facility project was completed to very high standard, meeting the Tier 1 International standards for the hockey (FIH) and was completed on time for the Hawkes Bay International Festival of Hockey.

The Ngaruawahia section of the 102km Waikato Expressway provides a four-lane bypass of Ngaruawahia and created a faster and safer link between Taupiri and Hamilton. The bypass connects to the Huntly section of the Waikato Expressway and the Te Rapa section in the south.  The Waikato Expressway Road of National Significance was completed in 2022 to improve safety and reliability, to reduce travel time between Auckland and Tirau by 35 minutes, and to reduce congestion on SH1.

Our work included construction of 9.5km of expressway between SH1B (Gordonton Road) and Horotiu, 1.5 million m³ of earthworks, seven bridges, 220,000m2 of pavement and surfacing, and a grade-separated interchange with Gordonton Rd.

A standout feature of the expressway is Te Rehu o Waikato (the Mist of Waikato); a 140m long, five span bridge which carries the motorway over the Waikato River.

The Waikato River is sacred to mana whenua and therefore bridge piers were not permitted within the water course. To comply, the bridge was designed with a steel ladder deck with the 55m main span supported on innovative v-shaped piers. The v-shaped piers feature artwork designed by a Waikato-Tainui master carver and depicts tuna whakaheke (eel migration). Pou whenua on top of the bridge feature ancestral figures recognising ancestral connections to the Taupiri-Horotiu and wider region.

The entire 1.5 million m3 of earthworks and 220,000m2 of pavement was constructed within just two years.

In 2013 Higgins Auckland were awarded the contract to re-align a portion of this iconic track as part of a $6m raceway upgrade.

The contract was won on the back of the Higgins paving expertise, as well as the client’s preference for the unique asphalt mix designed by Higgins technical support group.   Higgins reconstructed the three new corners along the back straight of the race track and was involved in the placement of specialist race track kerbs and the relocation of 3000m3 of clay/topsoil for new viewing areas beside the track.  Australian touring car legend Mark Skaife provided technical advice to the shaping of the subgrade.

Due to being one of New Zealand’s earliest cities, many of Christchurch’s sewers were built before the invention of precast concrete pipes, using unreinforced brick and concrete. As with brick buildings, these brick sewers are particularly vulnerable to seismic activity and some were severely damaged during the 2011 and 2012 earthquake. This highlighted the vulnerability of the infrastructure, and the need for strengthening and earthquake proofing.

Replacing the sewers would have caused major disruption to traffic and the community, so SCIRT opted to rehabilitate most of the pipelines using cured-in-place-pipe technology (CIPP). 

Pipeworks relined the egg-shaped and elliptical pipes, which vary in diameter from 450mm to 1,350mm, using a very thick structural liner to protect them from future earthquakes and liquefaction. With many of the pipes running down major arterial roads, careful logistics planning and extensive traffic management was required.

All sections of CIPP liner were installed to a high standard, with minimal disruption to traffic and surrounding residents. The scale of work to be completed made this the largest CIPP project ever undertaken in New Zealand. Due to the sheer volume of work, the CIPP liners had to be installed three times faster than normal – faster than any other large diameter CIPP project in Australasia.

The project had numerous unique aspects:

• All of the pipes were more or less permanently flooded
• Bypassing of sewer flows of up to 300 litres per second – pumped above and below ground in busy streets
• Major alterations to large manholes up to 4m deep were required including well pointing and trench shields
• All resin mixing was undertaken inside the "Red Zone" to reduce risk
• Confined space entries were required to open laterals in certain pipes.

Photo courtesy of Water New Zealand

Manawatu Gorge section of SH3 is a vital link between the eastern and western regions of the lower North Island.  On 18 August 2011 this link was severed by a large landslide, followed by other significant slips.  The project to reinstate SH3 was huge.

As the head contractor, Higgins was responsible for project management and ultimate project completion including coordination with consultants and subcontractors; management of the slip works and communication with NZTA and other key stakeholders. To stabilise the slope, five massive benches were built from the top down, each longer than a rugby field.  A track was built through bush at the top of the slope so equipment could be brought in.

This slip damaged the road far more extensively than any of the previous slips in the Gorge. Once the slip was stabilised a massive multi rebuild phase commenced to:

• totally rebuild a three span bridge
• repair two further bridges
• construct an 85m-long retaining wall
• construct retaining netting the size of a rugby field
• build 200m of pavement and railings.

In May 2012 the benching was completed and the road was cleared.  A total of 370,000 cubic metres of soil, rock and debris was removed from the site, enough material to overflow the Wellington Regional Stadium (Westpac Stadium). This combined with a vertical height of 155m made this the largest road landslide in New Zealand history. Stage two then began to fix the road bridgework damaged by the slip.  A truly collaborative team environment delivered this technically complex task in four months - an operation that would normally take up to a couple of years to plan and build.

By addressing the bottleneck in Auckland’s motorway system between Newmarket and the Auckland Harbour Bridge, the Victoria Park Tunnel created safer and faster trips for 150,000 vehicles a day.

As part of an alliance alongside the NZ Transport Agency, Beca, Higgins and Parson’s Brinkerhoff, we constructed the 440m cut and cover tunnel that carries three lanes of northbound traffic metres below Victoria Park, and widened the existing motorway through St Mary’s Bay. We modified the existing four-lane viaduct to carry southbound traffic.

Works took place in a complex, live traffic environment impacting on services, businesses and residential properties. However, great care was taken to minimise disruption. Preservation of key heritage sites was also an important aspect of the project, particularly the 1886-era Rob Roy Hotel that had to be moved to make space for the widened viaduct.

Urban design features opened up the area for the community, including a much-improved replacement skatepark, a new public plaza in front of the Rob Roy Hotel, a footbridge over the motorway to reconnect land and sea in St Marys Bay and a walkway through St Marys Bay that's protected from the motorway by a transparent noise wall.

The project won several awards:

• NZ Contractors Federation Award 2011 (Supreme winner)
• NZ Contractors Federation Award 2012 (Projects over $20 million)
• Public Relations Institute Award in 2012 (Government Communications)
• Roading Excellence Awards 2012 (Z Energy Excellence Award for a major Road Project) and HireQuip Best Practice Award for Environmental Sustainability
• International Road Federation (Global Road Achievement Award for Construction Methodology) 2012

Located north east of Palmerston North in the Manawatu District, Kopane Bridge is a significant regional commuting route. A new Kopane bridge was constructed 4m higher than the old bridge to protect the route from the consequences of possible flooding.  The project called for the construction of a higher bridge deck with new embankments leading up to and from the bridge which involved 100,000 m3 of earthworks and 1km of new roads.

As the Head Contractor, Higgins was responsible for managing the contracting along with specialist subcontractors to ensure the successful delivery of the project.  The contract allowed for a eighteen month contract period, but the team succeeded in delivering the project ahead of time within a twelve month period. 

Our construction of the South Western Interceptor in 1997 saw the first use of large diameter micro-tunnelling techniques in New Zealand.

We used a tunnel boring machine to install two km of 1900mm diameter pipeline in an environmentally sensitive area adjacent to the approach path to Auckland Airport.

Fifteen years later, we extended the pipeline to Manurewa to accommodate rapid population growth in Auckland’s southern suburbs.

Due to the complex ground conditions we used three different methodologies to install the 2.3km, 900mm diameter wastewater pipe: open trenching, directional drilling and pipe jacking. A tunnel boring machine was used for the pipe-jacking section.

We also constructed a new pump station to replace the one at Manukau’s Wattle Farm Reserve, which had reached the end of its serviceable life. The pump station was constructed using in-situ reinforced concrete wet-and-dry-well internal walls and pre-cast panel roof.

The project involved significant mechanical and electrical works, including installation of four 320Kw pumps, numerous 700-900mm diameter valves, pipework, HVAC system, cooling water system and odour removal. The project team was also responsible for managing the sub-contract electrical works, which included installation of a new control system, cabling, switchboard and float switches.

The extension to the South Western Interceptor and the new pump station provided for future growth in South Auckland in as well as reducing the frequency and volume of wastewater overflows to the Manukau Harbour.

The 1.5km road is stage 1 of the Ngaruawahia Bypass.  Taupiri Link connects to SH1B back onto SH1 at Taupiri.  The Huntly bypass connects the Ngaruawahia Bypass to the section at Ohinewai. The Tangata Whenua had extensive involvement in the Taupiri Link project as it is an area of high cultural significance.

Higgins managed and constructed the challenging project involving significant alignment changes and pavement upgrades to both State Highway 1 and 1B.  Traffic queues and wait times were eliminated and safety greatly improved at these very busy intersections. 

Higgins constructed a two lane roundabout at the intersection of SH1 and SH1B; a new single lane roundabout at Orini Road and SH1B; a new pedestrian/cycle bridge over the North Island main trunk railway; redirecting existing side roads to the roundabouts; shared walk/cycle ways and extensive landscaping works.

Higgins was the main contractor for the delivery of the Hawke's Bay expressway.  This involved all contract management activities including quality, safety and environmental management plans.  Higgins managed subcontractors for earthworks, box culverts and landscaping.  All pavement construction, surfacing and traffic management was undertaken by Higgins own teams.

The prospect of 133,000 people visiting New Zealand for the 2011 Rugby World Cup led to major infrastructure and building projects across the country. The Manukau Harbour Crossing (MHX) was just one example, aimed at creating a faster, safer connection between Auckland airport and the CBD.

By widening the existing SH20 between Mangere and Otahuhu and delivering a duplicate bridge across the Manukau Harbour, MHX significantly reduced travel time between the airport and Auckland CBD and improved connections between the communities of Onehunga and Mangere Bridge.

Built adjacent to the existing Mangere bridge (also built by Fletcher in 1982), the new 650m-long, twin box-girder bridge provided four lanes in each direction, plus two dedicated bus lanes – doubling current capacity. Five kilometres of new motorway was constructed on SH20, along with three-and-a-half kilometres of pedestrian and cycle routes and two kilometres of major water-main infrastructure.

The project was also a key milestone towards the completion of the long-planned Western Ring Route, connecting State Highways 16 and 20 and providing an alternative to SH1.

We delivered the project as part of the MHX alliance alongside Beca, Higgins and the NZ Transport Agency. The alliance’s delivery of the project led to the award of a major variation to the contract, the SH20A to Airport project.

Project Takatini was a NZ Defence Force project to make extensive improvements to infrastructure of the RNZAF Base at Ohakea.

Higgins was contracted in the Stage 1 to build the support network of civil works services and roading for the new Airforce Helicopter squadron facilities.  In the second Stage, Higgins was contracted to manage the construction of the heavy duty pavement which links the existing taxiways for the three squadron helicopter hangar.  The pavement constructed involved extensive asphaltic concrete. 

The Waka Kotahi NZTA project was designed to address delays and safety issues on the 2.7km stretch of SH2. Construction of the state highway involved the reconstruction of four lanes of live highway using a Higgins designed and manufactured deep lift asphalt. The interchange at the base of Dowse Drive and overbridge at Korokoro provide better connectivity to and from the state highway for Wellington motorists and residents on the Western Hutt hills of the Hutt Valley.