This project was to investigate and construct a new road link from State Highway 2a, de-conflicting traffic priorities on State Highway 29 to the Port of Tauranga.

Vitruvius acted as project manager through the investigation and onto the specimen design phase. This investigation took 2½ years to complete amid strong political and public interest.

Vitruvius also provided project management to oversee the compilation of tender documentation, tender process management and the appointment of a professional services provider to deliver the specimen design.

Article written by Henry Watson – Senior Rail Project Engineer

Vitruvius is proud to have supported Auckland Transport (AT) in delivering the Wiri Depot upgrade project which went into use in November 2024.

The 550m depot is the main maintenance and stabling facility for Auckland Transports new Electric Multiple Units (EMUs) trains. The project features 10 brand-new stabling roads built by John Holland between October 2023 – November 2024, where Neil Mason acted as the Engineer to Contract, with Henry Watson managing the day-to-day as the Engineer’s Representative.

The entire depot was built up from scratch, covering a number of disciplines containing earthworks, drainage, track, Overhead Line Equipment (OLE), lighting, signalling, Communications, Signalling and Rail systems (CSR), Electrical and Bulding services (E&B).

The depot is a crucial part of infrastructure for AT, serving as the hub for the new fleet for the City Rail Link (CRL). Each train visits the depot at least once a month for maintenance, undergoing minor inspections every 1,000 kilometres. As mileage increases, the inspections become progressively more comprehensive, ensuring the fleet remains in peak condition.

Wiri also marked the starting point of the Third Main Line, with a section of the new line completed in 2025 as part of a staged delivery programme. The additional track allows freight trains to operate independently of commuter services, reducing congestion and improving network efficiency.

It was an incredible project to be a part of, being able to watch the depot being built from the ground up.

Article written by Simon Cave – Sector Lead – Rail & Senior Principal – Project Management

KiwiRail engaged Vitruvius to lead the Digital Integration workstream for its European Train Control System (ETCS) Level 2 Programme in Wellington. This programme represents New Zealand’s first ETCS Level 2 installation and is a major step forward for the Wellington metro network, enabling increased service capacity through the removal of lineside signals and reduced train headways.

Vitruvius was appointed based on several key strengths, including our established working relationship with KiwiRail’s Digital Engineering team and deep understanding of their digital requirements, our long‑standing knowledge of the Wellington metro area developed through more than 15 years of work in the region, and our collaborative, relationship‑based delivery model. This approach ensures close integration with client teams and supports the detailed design of complex rail features such as turnouts and points of switch (POS), track alignment changes, level crossings, platforms and axle counters.

The ETCS Level 2 Programme spans the entire Wellington Electrified Area (WEA), covering approximately 105 kilometres of rail corridor. Vitruvius’ involvement has focused on early‑stage digital integration to de‑risk design, cost estimation and construction by developing a comprehensive digital twin of the network. This work has been critical in preparing the programme for downstream delivery as procurement and system design activities progress.

The ETCS system requires the installation of extensive lineside infrastructure across the network, including new Combined Services Route (CSR) ducting, balises, cabling and radio network upgrades to support GSM‑R communications. Delivering these works requires access to almost every part of the rail corridor. Establishing a detailed, accurate digital representation of KiwiRail’s existing infrastructure has enabled early identification and mitigation of key risks, clearer definition of scope, and greater certainty ahead of construction.

A core requirement of ETCS Level 2 is a precise understanding of the location and configuration of critical rail assets. Vitruvius’ digital integration work has focused on capturing, validating and digitising this information so it can be reliably used by the ETCS system supplier during detailed design.

The digital twin programme commenced with the establishment of a master survey control network across the WEA, followed by targeted surveying to fill gaps where point cloud data was not previously available. With full corridor coverage achieved, the focus has shifted to extracting key model features and associated asset data to support both the ETCS programme and broader network needs.

Beyond ETCS, the value of this digital dataset for long‑term asset management is significant. The work undertaken through this programme has created a strong digital foundation for future planning, maintenance and operational decision‑making across the Wellington metro network.

Vitruvius has been proud to partner with the New Zealand Housing Foundation (NZHF) to deliver 100 affordable homes for families. NZHF’s innovative ownership model enables families to initially purchase 60% or more of their home, with the opportunity to acquire the remaining share over time. Throughout this journey, NZHF provided comprehensive support, including mortgage assistance and ongoing guidance to homeowners.

Delivered across four stages, the project demonstrates a successful approach to medium‑density residential development in Ōmokoroa. As the area’s first development of this kind, it presented unique challenges due to departures from standard council requirements. These were addressed through close collaboration with local authorities, ensuring full compliance and a high‑quality outcome.

Beyond the technical and logistical challenges, the project is achieving its core purpose of delivering much needed affordable housing for New Zealand families. Vitruvius was honoured to contribute to this meaningful initiative and to help create a lasting positive impact for the community. Vitruvius played a key role throughout the project lifecycle, leading the Detailed Design phase, overseeing Construction Monitoring, and is managing the acquisition of legal titles for all housing lots. These responsibilities were critical to the project’s overall success and were delivered to a high standard.

KiwiRail initiated the Rail Network Rebuild (RNR) programme to prepare the rail network for increased service frequency and operational demand associated with the opening of the City Rail Link (CRL).

Vitruvius provided strategic advisory support during the early development of RNR, led by senior principals including Neil Mason and Terry Hodder. This work focused on establishing a robust framework to support network readiness and resilience under constrained access conditions.

The RNR involvement initially commenced under field engineering and asset management support, which subsequently transitioned into targeted technical delivery roles. This led to Vitruvius undertaking discrete rail infrastructure design packages, including:

• Drainage design for operational rail corridors
• Track design within constrained brownfield environments
• Complex turnout design, including works at Quay Park

Through this evolution, Vitruvius supported KiwiRail in addressing specific network constraints and asset upgrade requirements, contributing to improved network performance and constructability outcomes ahead of CRL commissioning.

Supporting one of KiwiRail and Greater Wellington Regional Council’s critical and high risk renewal projects in delivery and design.

Vitruvius supported KiwiRail’s Wellington Metro Upgrade Programme (WMUP) management team by delivering a range of critical roles across the WMUP III Wairarapa Tunnels Renewals Project. What commenced as drainage design, delivery support and MSQA services, led by Matt Stuart, evolved as the project progressed to include Engineer’s Representative services for the drainage contract, Project Director leadership provided by Neil Mason, and additional project engineering and project management support to enable successful delivery of the works within a complex operational environment.

The Remutaka Tunnel (renamed from Rimutaka in 2017), is an 8.8km single bore Railway tunnel constructed from 1951 to 1954 and opened in November 1955, replacing the Rimutaka Incline railway that had made its way over the Remutaka Hills since 1878 (now known as the Rail Trail to local hikers and bikers). The tunnel runs through New Zealand’s Remutaka Range and is the second longest railway tunnel in the country. The location of this tunnel and the regular use for freight and passenger services makes maintenance periods difficult to come by.

The majority of the components within this tunnel have not been replaced since the track was first constructed in the 1950s and the windows for renewals are particularly short given the amount of drainage and track that is to be renewed throughout, requiring an innovative and collaborative approach to construction. The hard deadlines for construction require designers, contractors, project managers, programmers, construction managers and commercial teams to work closely together to provide a proactive and safe plan of attack. The success of this project will come down to each stakeholder feeling a part of the team and buying into the project goals.

Drainage Design and Delivery

Designing a drainage system in a tunnel environment that is able to be safely removed, recycled at the next renewal and takes into account productivity/available track time is no easy feat. Vitruvius led the drainage design for both tunnels, responding to a number of complex principal requirements. A key consideration was designing a system capable of withstanding loads from track panel lifters used during track relay works through the tunnels. The solution also had to convey an unknown flow rate through the short circa 650m Maoribank and the significantly longer circa 8.8km Remutaka tunnel. Following initial site investigations, remote flow rate monitoring was installed to aid in the design of the drainage system and water samples were collected to test for the presence of contaminants and iron.

An initial concept design was produced for the internal tunnel drainage only with a number of recommendations to the client to ensure a whole system approach to upgrading the drainage had been considered. In order to progress to detailed design, Vitruvius requested further surveys be undertaken of the external tunnel drainage to identify the asset condition, location and outfalls. This meant a full system design could be provided to prevent downstream defects causing an overflow of the tunnel drainage.

The detailed design offered two solutions for differing scenarios within the tunnel, the more complex of the two for higher flow rates comprised of a Megaflo system throughout the tunnel with a layer of drainage metal, a filter layer of sand and geofabric working in unison to increase the design life of the solution and a walkway that provided adequate underfoot conditions for maintenance. For increased efficiency within the tunnel a second option for lower flow rates was also proposed that allowed for the removal of the Megaflo and sand from areas of the tunnel where the flow rate was considered lower than 0.2l per s.

The design underwent review, during which the construction team requested amendments to enable faster installation within the available work windows. Rapid turnaround of design reviews and approvals allowed these changes to be incorporated efficiently, resulting in a solution that was well‑suited to the tunnel environment and could be installed by the contractor within the permitted timeframes. The value of having a strong design manager and early contractor involvement, working collaboratively with the client, was clearly demonstrated in the lead‑up to site commencement.

Civil and Laydowns

On short notice, Vitruvius was engaged to act as Principal’s Project Manager and Engineer’s Representative for the newly awarded NZS 3915 contract to construct three laydown areas as part of the enabling works. With commencement deadlines looming and several critical risks unresolved, a proactive and collaborative approach was required to mitigate potential impacts to programme.

Through coordinated stakeholder engagement, legal and planning reviews, and the development of strong working relationships across multiple risk areas, these risks were effectively managed. This enabled the critical laydown works to commence and be completed without disruption to the project’s critical path drainage works. Vitruvius is proud to have supported the project team in navigating these challenges and delivering outcomes aligned to a shared project goal.

Project Director

Neil Mason, who was Managing Director of Vitruvius at the time, stepped in as Project Director for the Wairarapa Tunnels 1 and 2 delivery to support best practice long tunnel project delivery. Having worked on all of Aotearoa New Zealand’s long rail tunnels in some capacity, Neil brought a wealth of experience in the safe and practical delivery of complex tunnel projects. This depth of experience supported the WMUP team in delivering the programme of works within a highly complex safety and stakeholder environment – the kind of complexity Vitruvius thrives in.

Vitruvius initially began on the project in February 2023 with support and advisory requirements increasing over time. We were grateful to have joined our valued client on this project delivery journey and bring not just our rail knowledge, but our project delivery expertise as well in support of their project goals to safely deliver these critical works to programme. So far so good!

Vitruvius would like to acknowledge all of the fantastic people that are involved in delivering this project and their companies – Our Client and Partner KiwiRail, consultants Tonkin & Taylor, WSP and Aurecon, Track and Drainage construction – Titan Contracting Group, Civil and Laydowns – Mills Albert, Tunnel Ventilation – BEST Engineering, and the vast network of sub-contractors and suppliers that make a project of this scale a success.

The Western Bay of Plenty Transport System Plan (TSP) is a multi-partner initiative with co-governance from Tauranga City Council, Western Bay of Plenty District Council, Waka Kotahi, Bay of Plenty Regional Council, tangata whenua, Port of Tauranga, Priority One and KiwiRail.

TSP’s purpose is to take the Urban Form and Transport Initiative’s (UFTI) ‘Connected Centres’ vision for the Western Bay and focus on the first 30 years of transport planning required to make it happen.

Vitruvius was appointed as the independent Programme Director and Programme Manager, providing oversight of the delivery of the first phase of the TSP. This included establishing the project’s procedures, governance and delivering the System Operating Framework which informed an aligned Regional Land Transport Programme investment submission.

Our responsibilities included:

• Project management
• Project governance
• Stakeholder management
• Contract procurement and management
• Financial management and cost control
• Project reporting
• Risk management
• Strategy development
• Capability strengthening.