W2B Pacific Highway Upgrade - Section 5 Bridges
Maclean, New South Wales

Project Overview

The Pacific Highway Upgrade between Woolgoolga to Ballina (W2B) in northern NSW involved the duplication of approximately 155 kilometres of the national highway to a four-lane divided road.

JF Hull Holdings (as part of the BHA Joint Venture) was awarded a Construct Only Contract by Transport for NSW to construct 21 bridges between Maclean and Iluka (Portion B Section 5).

The bridges were positioned over 14 Floodplain Openings, with 3 Highway Overpasses for local roads, 1 Fauna Crossing and 1 bridge over an existing waterway. The combined length of all constructed bridges totalled 2400 linear meters.

Principal: Transport for NSW
Delivery Partner: Pacific Complete
Principal’s Contact: Matt Ross
Project Director: Clayton Smith
Project Manager: Dennis Vidulin
Project Foreman: Dave Prouten
Date Commenced: July 2017
Date Completed: March 2020
Contract Value: $69,048,057
Contract Value at Completion: $87,754,433

Scope of Works:

The access to the bridge sites and associated working platforms were provided by the client. Bridge piling was excluded from our scope and precast elements were supplied by the client.

JF Hull installed a total of 99 precast abutment & headstocks beams, each weighing in excess of 50t. 

Approximately 15,000m3 of concrete was poured for remaining in-situ substructures including abutments, headstocks and piers. Pretensioned precast concrete deck units were utilised and comprised a total of 69 Super T girders and 753 winged deck planks.

Largest precast elements installed were 60t Super T girders requiring a 750t mobile crane to carry out the installation. Night works and temporary highway closures were required to install girders over live traffic. All decks were cast in-situ concrete and finished with a mechanical vibrating truss screed. A total of 1216 precast parapets were installed on the bridges and connected to the deck via an in-situ concrete ‘stitch’ pours. JF Hull also completed the bridge approach works which included general fill and gravel pavement layers from underside of abutment sill beam to underside of foamed bitumen and AC layer. 

Finally, due to settlement issues, JF Hull managed the installation of approx. 13k of CFA and CIC ground improvement piles.

02
DJI_007405
DJI_011506
DJI_016808
DJI_018509
DSC_008520
J143---201701
J143---201703
J143---201704
J143---201710
J143---201711
J143---201712
J143---201713
J143---201714
J143---201715
J143---201716
J143---201718
J143---201719
J143---201721
J143---201722
J143---201723
J143---201724
J143---201725
J143---201726
J143---201727
J143---201728
J143---201729
J143---201730
J143---201731
J143---201732

Project Outcomes and Performance

Time Management

All works were completed within the agreed contractual timeframe. Interim bridge completion milestones were agreed and handed over progressively to meet the overall project staging and critical traffic switches.

The horizontal packaging strategy adopted by Transport NSW required multiple contractors on site at any given time. This required extensive and continuous coordination of works to ensure unhindered access to the bridge sites with minimal disruption and impacts to the bridge works. The project team worked collaboratively with the TfNSW delivery partner; Pacific Complete and other contractors to resolve any coordination issues and communicate any changes to the program.

JF Hull worked closely with the Pacific Complete to implement various safety initiatives and campaigns. These included the a Separate Yourself campaign which focused on plant and people movement and separation on site.  There was a significant focus on monitoring high risk activities through Fatal and Severe Risk (FSR) audits and Key Deliverable inspections. Various work activities and practices were reviewed and improved by project team members via Collective Insight workshops which involved engaging with work crews to facilitate discussions around making the workplace safer. Constant feedback from site and the workforce was encouraged through leadership works and the formation and implementation of Pit Crew membership and meetings.

The project team worked closely with TfNSW and Pacific Complete communication teams to ensure that appropriate notifications and explanations were provided to the local community and stakeholders. No formal complaints were received during the entire execution of the project.

Despite works near the Clarence River and within its floodplain, no major environmental incidences were recorded. Strict erosion and sediment controls were implemented at each bridge site and concrete waste was managed and recycled through purpose built concrete washout bays.

JF Hull were able to successfully exceed the contractual target for indigenous spending (> $1.3M) for the project. This was achieved through engagement with local indigenous owned businesses and employment and training of local indigenous staff and labour.

“All bridges were handed over defect free to the follow on contractor in timeframes agreed. BHA should be commended on their performance and management of their contract scope. BHA coordinated well with all contractors as well as performing well in all key performance areas. It has been a pleasure working alongside BHA to successfully deliver the bridge scope of works for portion B.”

Matthew Ross, Principals Authorised Person,  10/4/2020