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Te Rapa Overlay


Client: New Zealand Transport Agency (NZTA)

Completion date: May 2014

Capability: Roads and bridges, Surfacing

The Waikato Expressway is one of New Zealand’s seven roads of national significance and is designed to move people and freight between the five largest population centres, safely and efficiently. Once complete, the Waikato Expressway will provide a continuous divided four-lane highway that spans 102km between Auckland and Cambridge and reduces the length of State Highway 1 by six kilometres.

While the construction of the 7.2km section was completed in December 2012 by the Te Rapa Alliance, a consortium of Fulton Hogan, Opus International Consultants and NZTA, Fulton Hogan’s Waikato region, was appointed to surface this entire new section of expressway twelve months later.

One of a kind

This has been the largest single surfacing job the Waikato region has undertaken. In total, 100,525m², or 5,612 tonnes of OGPA, were laid, to an average depth of 29.5mm. The overlay went straight over the chipseal surface, with only small sections of levelling required – 60tonnes over the whole job.

This job saw the crews go back to basics, as it was paved without the use of mechanical levelling controls. Despite this, the team achieved a NASRA score of 23 for the project. It took more than 17 shifts to complete the project and the team’s biggest production night saw 503 tonnes laid with no injuries – achieving Fulton Hogan’s goal of Zero Harm for the project.