Manukau Bus & Train Interchange


Cox Architecture


NZ Strong


Auckland, New Zealand





Featured, Anchor & Cable, Fall Arrest, Transport, Kingspan Safepro2


The Manukau Bus and Train Interchange is at the heart of the connected public transport network for South Auckland, connecting bus users to trains and other buses. The project is a critical component in delivering South Auckland's new network as part of the more integrated public transport network for all of Auckland. As one of Auckland Transport’s integrated transport hubs, it’s setting a precedent for a new and simpler way to travel. Connecting buses and trains at interchanges like these encourages more people to take public transport and provides a more efficient service into the CBD.

On a 1:100 gradient, 23 bus bays sit alongside an amenity building comprising a central ticket kiosk, layover space for bus drivers, operations rooms, and retail/convenience stores. Passengers connect seamlessly to the surrounding streets, the Manukau train station, Hayman Park and Manukau City.

Key features of the building include; 

  • No-one can miss the unique sawtooth roof design. Every piece is different, allowing natural light to flood into the building. Roof planes run in a north-south direction to maximise the amount of natural light. 
  • Automated louvres and natural ventilation provide cooling and north- and northeast-facing façades allow direct sunlight to stream in during cooler months. A 12m deep cantilevered canopy offers protection from the weather and flexibility for future bus bay layouts.
  • Storm water runoff from the bus bays and bus manoeuvring area will be treated through rain-gardens located within the station area, prior to discharge to the wetlands in Hayman Park.


With a large amount of windows and internal gutters, clearing and maintenance was identified as the main requirement for access to the roof. Other height safety requirements identified for the Manukau Bus & Train Interchange included:

  • Completing regular washing of sawtooth windows. 
  • Undertaking regular roof washdown as stated in the roofing manufacturer’s warranty.
  • Completing regular gutter cleaning.


Given the larger surface area of each sawtooth roof, a Kingspan Safepro2 Cable Cable System was chosen to provide the user with continuous hands free connection while on each level of the sawtooth roof. Each cable system runs along the internal guttering of each roof level, positioned 2.5m back from the edge of a roof as a minimum. This ensure users are working in restraint technique, provided they use a standard issue 2m lanyard. 

The roof of the building is Kingspan 0.9BMT Aluminium Kingzip SF 400 PVF 2 Finish, which is another reason why the Kingspan Safepro2 Cable System was also chosen. Kingspan state that only Kingspan approved height safety and fall arrest systems should be installed into Kingspan roofing profiles. 

The Kingspan Safepro2 Cable lines were surface mounted via a base plate that was riveted to the roof sheeting using 8mm self-sealing star rivets. Both brackets, baseplate and cable are all manufactured from 316 grade stainless steel to ensure long life and durability, which is especially important due to Auckland often receiving wild and wet weather during the winter months. 

Working alongside NZ Strong and Becca Engineers & Consultants, installation of the height safety solution was staged as various roofing levels were completed and edge protection removed. 



Working with PBI Height Safety ensures ongoing support and certification of the height safety and fall protection systems, and PPE.

In accordance with the AS/NZS 1981.4:2009 Standards - Industrial fall-arrest systems and devices, Part 4: Selection, Use and Maintenance, - and manufacturer warranty conditions, the Kingspan Safepro2 Cable lines require an annual recertification inspection. Recertification of the installed systems includes:

  • Inspection of line anchorage points and rail support anchorages in accordance with AS/NZS 1891.4.2009, Section 9: Inspection, Maintenance and Storage, Clause 9.3.3.
    • Anchorages shall be visually inspected for signs of deterioration which might make them unserviceable, together with any other requirements contained in the manufacture' instructions.
    • Drilled-in anchorages such as friction or glued-in anchorages shall be proof tested in accordance with Clause 3.1.2(g) as part of each inspection.
  • Visual inspection for any modification or deterioration of the parent structure which might lead to a loss anchorage strength.
  • Inspection of the condition and correct operation of line tensioners and line energy absorbers on horizontal lifelines.
  • Looking for evidence of wear, cuts, looseness, extension, inter-strand wear, corrosion, stiffness, brittleness or fraying of steel cables, ropes or webbing used as horizontal flexible lifelines or vertical lines used in conjunction with Type-1 fall-arrest devices with special attention given to lines in the vicinity of horizontal lifeline intermediate anchorages.
  • Inspection of integrity of the cable terminations.


  • 2018 New Zealand Institute of Architects (NZIA) Auckland Awards - Public Architecture



Installed Systems

No product.

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