Coffs Harbour Bypass

Project Details

Engaged by Ferrovial Gamuda JV, Hawthorne Civil delivered a significant package of form, reinforcement and pour works for multiple complex bridge structures along the Coffs Harbour Bypass.

The scope comprised two single-span bridges, one triple-span bridge and two viaduct-style bridges, including structures spanning up to 240 metres across the north–south rail corridor with piers reaching 15 metres in height and the construction of a 300 m³ deflection wall. Works were undertaken adjacent to a live rail environment, requiring carefully managed temporary works, bespoke formwork design and detailed staging to maintain rail operations and ensure safe construction.

Hawthorne Civil worked closely with Ferrovial Gamuda and Transport for NSW during early project phases to improve constructability and streamline delivery. This collaboration led to design refinements, including modifications to girder installation methodology on Bridge 12, enabling temporary rail removal directly from the bridge rather than from beneath, significantly improving safety and efficiency.

Steel formwork systems were utilised to reduce environmental waste and improve build consistency, while reinforcement was preassembled at ground level to minimise working at heights and accelerate construction. More than 80 per cent of the workforce was sourced locally, supporting regional employment and suppliers across cranage, concrete pumping and materials.

The project demonstrates Hawthorne Civil’s capability to deliver large-scale, high-risk bridge works within live rail corridors, combining technical expertise, constructability input and strong safety and environmental performance.