Ferrovial Construction brings global infrastructure expertise and a strong track record in complex transport projects. Gamuda contributes innovative engineering solutions and regional delivery capabilities. Together, the joint venture is committed to delivering the Coffs Harbour bypass project as a safe, efficient, and sustainable infrastructure that meets the needs of government clients and the broader community.

The Coffs Harbour bypass project was established by Ferrovial Construction (Australia) and Gamuda Engineering to deliver the $1.6B Coffs Harbour bypass project in New South Wales, a major government initiative led by Transport for NSW (TfNSW), the client. The Australian and NSW governments are investing in the NSW north coast. The 14-kilometre Coffs Harbour bypass project will boost the regional economy and improve connectivity, road transport efficiency and safety for local and interstate motorists.

The PVC Lined Trailer Engineering & Safety initiative is a proactive and scalable solution developed in response to a serious safety issue involving quad-axle dog trailer rollovers on the project. With “quad dog” trailers comprising 90% of the local market, banning them was deemed impractical. Instead, the project team collaborated with contractors and suppliers to develop and implement a retrofit solution using 6 mm ultra-high molecular weight polyethylene liners in the trailers.

After a concerted effort to research options, the team arrived at a promising solution that could provide positive outcomes not only for its project but potentially for the industry as a whole. The liners significantly reduced tipping angles from 50° to 39°, improved material discharge, eliminated the need for chemical flow agents, and extended trailer life. The initiative was embedded into the project’s risk register, Safe Work Method Statements, and minimum plant safety requirements—exceeding the client’s standards. It is now a mandatory requirement for all quad dog trailers operating on the project.

Execution was driven by clear safety and efficiency goals, structured planning, and strong collaboration across internal teams and external stakeholders, including TfNSW, SafeWork NSW, and local suppliers. A two-week trial period validated the solution, and full implementation was achieved within two months across 17 trailers. The initiative has since resulted in zero rollovers over the past two years, improved productivity, reduced maintenance costs, and an enhanced safety culture. The successful implementation is supported by data: in the initial 6 months, when two quad dog trailer rollovers occurred, 2.4 million cubic metres of material were hauled, compared to 4.9 million cubic metres since the implementation of the PVC liners, with no quad dog rollovers experienced.

Beyond internal success, the initiative is influencing broader industry practice. It has become a minimum standard for the Coffs Harbour bypass project and is expected to be adopted more widely once industry stakeholders realise the benefits. The team has welcomed contractor and client enquiries to replicate the solution, and discussions are underway to update the transport minimum requirements. The initiative has also won a global Ferrovial innovation award, and opportunities exist to share its outcomes further at industry forums.

The PVC Lined Trailer Engineering & Safety initiative stands as a benchmark for effective risk mitigation, demonstrating how engineering controls can drive safety, efficiency, and cultural change across the infrastructure sector.

For more information about the Coffs Harbour bypass and the PVC Lined Trailer Engineering & Safety initiative, visit https://www.nsw.gov.au/driving-boating-and-transport/projects/coffs-harbour-bypass.