The Kāpiti Expressway, which opened in February last year, may have 49 kilometres of lane work that needs replacing.
The Kāpiti Expressway opened in February last year. Photo: Supplied / NZTA
It is the second time the New Zealand Transport Agency has had to replace some of the road, even though it's still relatively new.
The expressway gives commuters a quicker route between Paekakariki and Ōtaki.
Transport Agency senior project manager Chris Hunt said the problem with the roading was very disappointing.
He said the agency was putting much effort into addressing the problem and learning from it.
It hasn't been finally decided how much of the road will need to be replaced, but the cost could be in the millions of dollars.