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 is a major road infrastructure project in New South Wales. The PVC-lined trailer, an Engineering and Safety initiative, has been successfully implemented on the project.

The Australian and NSW governments are investing in the 14-kilometre Coffs Harbour bypass project on the NSW north coast. The bypass will boost the regional economy and improve connectivity, road transport efficiency and safety for local and interstate motorists.

Ferrovial Gamuda Joint Venture is delivering major construction for the Coffs Harbour bypass project, which commenced in 2022 and is expected to open to traffic by the end of 2026, with completion anticipated in 2027. This work is being delivered under Transport for NSW’s first collaborative design and construct contract.

The project will deliver a four-lane divided highway between Sawtell Interchange and Sapphire Beach Interchange involving 11 kilometres of new highway and 3.4 kilometres of upgraded highway, three tunnels, 16 bridges, 16 fauna connections, a bus interchange and improved pedestrian and cyclist paths.

During the early stages of construction, the Coffs Harbour bypass project team identified a critical safety issue: two Quad dog trailer rollovers occurred within a four-month period. Recognising this as an industry-wide problem, the team sought a practical and scalable solution that could be implemented without banning the widely used trailer type.

In collaboration with truck contractors, the Coffs Harbour bypass project developed and trialled the installation of 6mm PVC liners in the rear bins of Quad dog trailers. These liners, made from ultra-high-molecular-weight polyethylene, reduce friction during tipping, allowing material to discharge faster and at a lower tipping angle. This significantly lowers the trailer’s centre of gravity, reducing the risk of rollover. The liners also extend trailer wear life, eliminate the need for material flow agents, and improve overall operational efficiency.

The initiative was researched, trialled, and fully implemented across the fleet within two months. It was embedded into the project’s safety protocols, asset management systems, and risk registers. Since implementation, for the past 2.5 years, the project has reported zero trailer rollovers. The solution has delivered measurable improvements in safety, productivity, and cost efficiency. It has also received recognition with other major infrastructure projects and contractors and is being considered for broader industry adoption.

The PVC Lined Trailer Initiative exemplifies process improvement through engineering innovation, stakeholder collaboration, and proactive risk management. It has created lasting value for the project, its workforce, and the wider industry, setting a new benchmark for trailer safety in infrastructure delivery.

For more information about 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.