KIWIRAIL MECHANICAL

0800 801 070, Option 0

HUTT WORKSHOPS

Elizabeth Street

Moera, Lower Hutt

New Zealand 5010

PO Box 36005

Wellington Mail Centre

Lower Hutt 5045

Ph: +64 4 587 1800

Fax: +64 4 587 1736

HILLSIDE WORKSHOPS

300 Hillside Road

South Dunedin

New Zealand 9044

PO Box 2146

South Dunedin 9044

Ph: +64 3 479 3470

Fax: +64 3 479 3209

• Overhaul • Refurbish • Rebuild • Components • Test • Inspection • Manufacture • Design • Inventory • Fabrication • Foundry • Machining • Traction Systems •

A strong traditionof engineeringprovides thefoundation of expertisethat exists in ourworkshops today

Hillsideand Hutt

Workshops– a track recordof engineering

excellence

KiwiRail has manufactured and assembled rolling stock in

New Zealand since the inception of the railways in the late 1800s.

We have a strong tradition of engineering that has provided the

foundation of expertise that exists in our workshops today.

The KiwiRail Mechanical business provides mechanical support to

the New Zealand rail industry and other markets. Wide-ranging

knowledge and experience in the New Zealand rail industry’s

regulatory and statutory framework includes commissioning and

type testing of new vehicles, together with extensive capability in

design, manufacture, maintenance and overhaul. Skills and resources

are concentrated at two sites, Hutt Workshops in Wellington and

Hillside Workshops in Dunedin, with both sites benefitting from

excellent road and mainline rail connections. Hillside has developed

a depth of fabrication expertise around passenger carriage and

freight wagon builds, while Hutt Workshop’s focus is on component

manufacture, electric motors and heavy locomotive overhauls /

rebuilds.

Engineering capabilities are also being used by customers outside

the rail industry, from power generation and shipping, mining and

forestry, to irrigation and decorative castings. KiwiRail’s workshops

are a major force in New Zealand engineering, with 400 staff across

two sites including electrical engineers, mechanical engineers, trade

qualified employees (maintenance and diagnostic), fitters, fabricators,

a range of semi-skilled workers, engineering support and registered

engineers.

Modern efficiency and quality standards are used across everything

we do, including the the “5S” principles, which provide the basis for

continuous improvement and maintain workplace efficiency in

production environments. Both sites are ISO accredited.

This site has manufactured rolling stock for theNew Zealand rail industry since 1875, and morerecently it has expanded its unique skills base andheavyweight capability to all engineeringapplications.

Hillside Workshops is one of Dunedin’s best-knownlandmarks with eight hectares of open yard andnearly three hectares of covered floor spaceincluding on site foundry, machining,assembly, paint and finishing facilities.

Products and Services

• Specialised welding processcapability

• New rail rolling stockmanufacture

• Steel componentsmanufacture for rail

• Civil structure manufactureand refurbishment

• Refurbishment of rail wagons

• Rebuild of freight, passengerand locomotive bogies

• Locomotive refurbishment andupgrade programmes

• Steel and iron castings

• Rail componentry andinventory

• Smelter industry components

• Mining industry components

• Stainless steel valve bodies

• Heat-resistant castings.

Projects

• C class flat-deck wagons

• CE class coal hopper wagons

• YJ class ballast hopper wagons

• SA and SD class passengercarriages for Auckland

• SW, SWS and SWG classpassenger carriages for theWellington-Wairarapa service

• AK scenic carriages for tourismexperience trains

• GT class car carrier wagons

• Locomotive bogie processimprovements

• YJ class wagon controls fit-out

• High quality passenger bogierefurbishment – one millionkilometres before overhaul

• ZH class box wagonsrefurbishment

• Refurbishment of DSG shuntlocomotive

• Supplier of stainless steel valvebody castings

• Research and development ofhigh temperature materials

• Turbine casings for powerstations.

Major Resources

• NZ’s largest heavy engineeringfacility

• 10,500m2 floor area in twoworkshops

• 100 tonne overhead crane

• 18 metre bed profile cuttingmachine – plasma and oxy-acetylene processes

• Internal fit-out of passengercarriages

• Large capacity grit blast andpaint booths

• 5 tonne arc furnace

• 2 tonne hot heel inductionfurnace

• 500kg high frequencyinduction furnace

• Heat treatment andspectrometer capability

• Materials testing laboratory

• Machining facility with CNCmachines and variousspecialist machines

• Butler Plano mill (9m bed)

• 3D modelling software.

Testing & Inspection Services

• IANZ accreditation since 1991

• Destructive and non-destructive testing

• Mechanical testing equipmentfor strength, toughness andhardness

• Radiographic (x-ray) testing

• Surface methods (crackstesting) equipment

• Weld testing and inspection

• Lloyds accredited foundry.

The Hutt Workshops site has a long history of railengineering, having been established in 1929-30as a locomotive manufacturing and maintenancefacility. Today, as a KiwiRail-owned facility, itcontinues to provide a range of engineering services,notably around component manufacture andlocomotive overhauls.

In recent years, Hutt Workshops’ main focus hasbeen on overhaul programmes and refurbishmentprojects, of which many are extensive and requirethe facility’s specialist skills, capabilities, plantand tooling.

Projects

• EO class locomotiverefurbishment

• Freight wagon overhaul andrefurbishment

• Diesel engine overhauls

• Electric traction systemoverhaul

• DX class locomotive rebuildand upgrade.

Major Resources

• High stud engineering facility

• 40,000m2 floor area

• 100 tonne overhead crane

• Electrical systems unit

• Traction motor test bay

• Wheelset production.

Testing & Inspection Services

• “5S” Continuous Improvement

• ISO9002 accreditation

• Traction motor electrical loadtesting

• Brake component test facility

• Locomotive load bankingfacility

• Woodward governor testing.

The Hutt workshops’ site also houses KiwiRail’selectrical equipment facility that carries out overhauland refurbishment of electrical systems includingtraction motors and alternators for heavyapplications.

The wide ranging inventory warehouse facilities atHutt Workshops are also the national logisticscentre, including an inventory of spares andconsumables for operations around the country.

Products and Services

• Major rolling stock overhaul

• Heavy maintenance andoverhaul of locomotives (dieseland electric)

• Heavy maintenance andoverhaul of passenger fleets

• Maintenance and overhaul offreight rolling stock

• Refurbishment of rolling stock

• Diesel engine overhaul – stripdown, rebuild, remanufacture

• Fabrication

• Electrical systemsmaintenance and overhaul

• Wheelset, axles and brake discproduction

• Refurbishment of rail wagons

• Rebuild of freight, passengerand locomotive bogies

• Locomotive refurbishment andupgrade programmes

• Steel and iron castings

• Rail componentry andinventory.

A track recordof engineering

excellenceWINNER – Otago Chamber of

Commerce Westpac Business ofthe Year Supreme Excellence

Award 2004

WINNER – NZ Casting ofthe Year Award 2002

IPENZ – Excellence Awardfor Mechanical andManufacture 2005

Hutt WorkshopsHillside Workshops