An iconic journey Pacific Highway upgrade 1996–2020

Aerial view of the Contents Nambucca Heads to Urunga project

Forewords 5 The long and winding road – history of the Pacific Highway 6 Tragedy sparks next chapter of highway upgrade 12 Pacific Highway upgrade – By the numbers 13

The sections

Hexham to 14 Port Macquarie to Coffs Harbour 22 Coffs Harbour to Ballina 30 Ballina to the Queensland border 38

Savings lives was driving force behind the upgrade from day one 46 Upgrade leaves behind legacy of innovation 48 Caring for the environment came naturally 50 An upgrade built for the people, by the people 54 Connection to Country at heart of upgrade 56 An economic boost – now and into the future 58 Opportunity knocks for bypassed towns 60 Highway upgrade a game changer for movement of freight 62 Keeping workers safe has been no accident 64 Then and now 66

COVER: The new bridge over the Clarence River at Harwood, built as part of the Woolgoolga to Ballina project

BACK COVER: Sun sets on the new bridge at Harwood Pacific Highway upgrade – 1996-2020 3 The Banora Point upgrade at night in October 2012

4 An iconic journey Forewords

Highway upgrade will leave a lasting legacy The Pacific Highway Since 2013, the Liberal and Nationals The horrific Cowper project has transformed communities is an iconic stretch Government has committed more than and Clybucca bus along the North Coast, delivering of road. Since it was $5.64 billion towards the duplication crashes, which new opportunities for businesses and first sealed in 1958, and it has been my pleasure to oversee happened within tourism and supporting local economies it has been the key the past three years of these works as months of one throughout construction. link between Sydney Minister for Infrastructure. another in 1989 and This book details the journey that we and Brisbane. claimed the lives of This book provides a history of the have been on since 1989, the stories 56 people, started a It is both a significant freight route, highway and the upgrade program, of those who worked on the upgrade conversation about the need to improve keeping the Australian economy since it began in 1996 and celebrates and the difference it has made to the Pacific Highway to ensure safer moving, and an important part of many this story of achievement. It shows communities all along the New South journeys for everyone who uses it. Australian family driving holidays and what can be done when governments Wales North Coast. the stories that go with them. work together to benefit the It has taken 31 years to get here, From the people who have worked communities we serve. upgrading more than 657 kilometres of Boasting almost 660 kilometres of four- on the upgrade over 20 years to road to dual-carriageway, building about divided road, travel time along the A better Pacific Highway means a safer the communities that have been 600 bridges, and bypassing more than Pacific Highway has been reduced by commute for motorists – that’s what we transformed, it captures the history 30 towns and villages. more than two and a half hours, and are delivering. of the most significant regional road fatal road crashes by more than half. It’s delivered a safer, more efficient infrastructure project in our State’s I want to thank every single worker, dual-lane highway from Hexham to the history and the legacy of that project on The Pacific Highway duplication business and motorist involved – this is Queensland border. communities, businesses and individuals. program has been a 25-year long a great infrastructure success story. effort and speaks to a very productive Since 1996, the NSW and Australian The Hon. Paul Toole, MP Michael McCormack partnership between the Australian and Governments have invested more Deputy Prime Minister NSW Minister for Regional Transport governments. than $15 billion to upgrade the Pacific and Roads Minister for Infrastructure, Transport Highway into a world-class highway, and Regional Development fit for the future growth of New South Wales. The multi-generational

Pacific Highway upgrade – 1996-2020 5 The long and winding road – history of the Pacific Highway The long and winding road

For almost 100 years the Pacific Highway, originally the North Coast Highway, has

provided a vital link between Sydney and Bogged vehicles on the Pacific Highway between the Queensland border. But it hasn’t always Brunswick Heads and Murwillumbah (c1930-31) been the smooth road motorists enjoy today. 1930s 1930s: highway relocated in September 1933: opening of old bridge Wide rivers and mountain ranges made building roads along the east coast over Myall River, Bulahdelah very difficult. In fact, it was not until 1909 that a continuous route, similar to the 1931: opening of bridge over Brunswick River, Mullumbimby March 1934: Dirty Creek Range deviation Pacific Highway, was available between Hexham and Tweed Heads. And even then (original) completed there were few bridges over the rivers, with crossings being made by ferries. 29 May 1931: highway renamed Pacific Highway and extended from Hexham to December 1934: opening of Boyds Following are some of the key dates in the development of the highway up until 1996. North Sydney. Route altered to follow Bay Bridge over Terranora Creek, Tweed Heads direct route between Bangalow and Ewingsdale over St Helena Hill March 1935: opening of old Raleigh Bridge over Bellinger River, Raleigh June 1931: reconstruction between opening of Mororo Bridge Murwillumbah and Tweed Heads June 1935: 1920s over the Clarence River North Arm completed 1936: Long Cutting deviation, south of 7 August 1928: December 1931: opening of bridge over proclaimed State Urunga, completed Nambucca River, Macksville Highway No. 10 1936: Five deviations completed in and named North 1932: opening of old bridge over Tintenbar Shire Coast Highway Stewarts River July 1936: opening of old Barneys Point between Hexham and 1932: Korora deviation replaced Bridge over Tweed River, Banora Point Tweed Heads Old Coast Road route between Korora December 1938: Burringbar Range September 1928: and Moonee Beach reconstruction completed, including opening of deviation and old bridge over 1933: opening of bridge over Lansdowne deviation at Billinudgel Kalang River at Urunga River, Coopernook 1939: Herons Creek deviation completed Cars climbing Burringbar Range, 1929: Ulmarra deviation 1933: opening of bridge over Dawson 1939: concrete pavement completed south of Murwillumbah, in September 1936 completed. River, Cundletown between South Grafton and Ulmarra.

6 An iconic journey The Pacific Highway in September 1949 The Pacific Highway, Tweed Heads, showing the state at Emigrant Creek, south of Newrybar border crossing at Coolangatta in May 1949

Building waterbound macadam pavement, five kilometres south of Coffs Harbour, in September 1951

1950s 1950: Boambee deviation completed 1957: deviation north of Woolgoolga June 1950: Repton bypass completed completed August 1952: highway re-gazetted June 1957: Wang Wauk to Bundacree between 12 Mile Creek and Taree via Creek reconstruction and sealing completed Karuah, Bulahdelah and Nabiac December 1957: opening of bridge over The Pacific Highway, six kilometres north of , Karuah Telegraph Point, between Port Macquarie December 1952: opening of Hexham and Kempsey, in September 1949 Bridge over Hunter River, replacing ferry 1958: Coopernook deviation completed 1953: deviation at Cassons Creek, north 1958: McGraths Creek deviation, south of 1940s of Corindi Beach, completed Urunga, completed 1954: opening of bridge over Brunswick April 1958: Pacific Highway sealing 1940: opening of second bridge over March 1945: route altered between Camden Haven River Tyagarah and Billinudgel, passing River, Brunswick Heads completed 1940: Bulahdelah to Wang Wauk through Brunswick Heads December 1955: Fernvale deviation March 1959: opening of bridge over section constructed 1949: reconstruction between completed Wallamba River, Nabiac May 1940: opening of Repton and Boambee completed. 1956: deviation on approach to old Shark November 1959: opening of bridge over over the , Taree Creek bridge, near Maclean, completed , Kempsey.

Pacific Highway upgrade – 1996-2020 7 1960s December 1961: opening of over and deviation, replacing Blackmans Point Ferry March 1962: opening of bridge over Balickera Channel 1963: opening of bridge over Ghinni Ghinni Creek, Jones Island 1963: Herons Creek bypass completed December 1963: opening of Karuah to Bulahdelah reconstruction, completing realignment between 12 Mile Creek and Taree

April 1964: opening of bridge over ABOVE: New Richmond River at Wardell and concrete bridge deviation, replacing Burns Point Ferry alongside old 1965: deviation on south side of low-level bridge Myall River, Bulahdelah, completed at Wootton in February 1960 1965: deviation on southern approach A dozer and scraper working on highway realignment to Macksville completed about 17km from Karuah in August 1960 May 1965: Woolgoolga deviation completed 1966: realignment through Bulahdelah completed 1966: deviation at Cunninghams Creek, north of Woolgoolga, completed Widening and realignment at Sextons Hill, Tweed Heads, August 1966: opening of Harwood in June 1964 Bridge over Clarence River South Arm, replacing last remaining ferry crossing on Pacific Highway 1968: Newrybar deviation completed July 1968: Grahamstown Dam deviation completed November 1969: opening of bridge over Myall River, Bulahdelah (replaced 1933 bridge).

Concreting during construction of the bridge over the Hastings River, The , seen here under construction, near Port Macquarie, in March 1961 opened in 1966, replacing the ferry

8 An iconic journey Construction of the Bellwood deviation, bypassing Nambucca Heads, in February 1979

Climbing in the Burringbar Range, 40 kilometres north of Bangalow, Work in progress at Clybucca Flat in June 1970 in June 1976

1970s 1971: deviation at Tabbimoble completed 1975: Telegraph Point to Cooperabung 1971: Korora deviation completed Range deviation completed May 1971: opening of Lower 1976: Sandy Beach deviation completed Warrell Creek Bridge August 1976: reinforced concrete March 1972: opening of Kalang River pavement at Clybucca Flat completed Bridge, Urunga 1978: deviation at Two Mile Creek, near 1973: Tumbulgum deviation completed Moorland, completed April 1974: opening of bridge over 1978: Cooperabung Range Wilson River, Telegraph Point deviation completed (replaced 1902 bridge) 1978: dual carriageways at Oak Ave, near Construction of the Cooperabung deviation, June 1974: Newee Creek Chinderah, completed. 22 kilometres south of Kempsey, in November 1974 deviation completed

Pacific Highway upgrade – 1996-2020 9 1980s 1980: completion of multiple deviations 1986: Smiths Creek deviation, at Condong, Eungai, Double Crossing Kundabung, completed Creek, Corindi Beach 1986: Shark Creek bridge and deviation 1980: Marshalls Creek reconstruction, completed Billinudgel, completed 1986: deviation at Devils Pulpit State December 1980: Bellwood deviation at Forest completed Nambucca Heads completed October 1986: Chatsworth Island 1982: Kerr Street realignment, deviation completed Ballina, completed December 1986: opening of Wang Wauk 1982: Tyagarah deviation completed, River Bridge replacing level crossing Dirty Creek Range deviation 1982: Burringbar railway bridge March 1987: completed completed 1983: Eungai railway bridge completed April 1987: Hexham Bridge duplication completed June 1983: Deep Creek deviation completed September 1987: reconstruction and realignment just south of Maria River 1984: Cooperabung Range deviation completed completed 1984: deviation at Jacky Bulbin, north of November 1987: Englands Road to Mororo, completed Arthur Street duplication, Coffs Harbour, completed 1984: Sextons Hill completed December 1987: Warrell Creek deviation 1985: Wedding Bells deviation, south of completed Corindi Beach, completed September 1988: Maria River duplication 1985: opening of new Boyds Bay Bridge completed over Terranora Creek, Tweed Heads April 1989: deviation from Alipou July 1985: opening of Tweed Heads Creek to Swan Creek, north of Grafton, bypass stage one completed.

Duplication at Maria River, Aerial view of the highway at Condong, south of Kempsey, on opening day north of Murwillumbah, in August 1980. in September 1988 The previous alignment can be seen on the right

10 An iconic journey Opening day for the dual carriageway at Possum Brush, north of Nabiac, in August 1991

1990s January 1990: Tomago Road to Masonite Road duplication completed December 1990: Herons Creek deviation, Ryans Road to 1km north of , completed June 1991: Swan Creek duplication completed August 1991: Possum Brush dual carriageway completed April 1992: Christmas Creek deviation completed A school bus negotiates the November 1992: Tweed Heads bypass narrow highway at Swan Creek, stage 2 completed about 10 kilometres north of Grafton, in January 1990 May 1993: Possum Brush dual carriageway extended south to Failford Road and north to Rainbow Flat June 1993: Cowper deviation completed November 1993: Herons Creek deviation, Herons Creek to Ryans Road, completed December 1993: Mororo Bridge duplication completed December 1994: Bangalow bypass (first carriageway) 1996: agreement between Australian and NSW governments to duplicate the Pacific Highway between Hexham and the Queensland border. Construction of the overpass at the Oxley Highway intersection, built as part of the View looking along the Tweed Heads Source: OzRoads.com Herons Creek deviation, in June 1990 bypass construction taken in June 1990 Photos: Transport for NSW library

Pacific Highway upgrade – 1996-2020 11 "The road was so horrendous that it was rare for a week to go Tragedy sparks next chapter by – or a month – where nobody was killed.”

Dr Ray Jones, Cowper of highway upgrade first‑responder and spokesman for Doctors for a safe Pacific Highway

Prior to the mid-1990s, most of the Pacific Highway from Hexham to the Queensland border was two-lane undivided highway.

This popular route for travellers and These tragedies prompted the coroner freight passed through more than to recommend the entire Pacific 30 towns and villages and meandered Highway be upgraded to divided dual through hilly terrain that prevented carriageway to improve safety on B-Double trucks from using the route. the increasingly busy corridor. By the late 1990s, there were more than The Pacific Highway had a higher 100 head-on crashes and more than fatality rate than other major highways. 50 fatalities annually. An upgrade was required to meet road transport needs between Photos: The Daily Examiner Sydney and Brisbane. There were also In 1989, two catastrophic The Cowper bus crash in 1989, in which 21 people died, was the first of two major bus safety concerns with heavy vehicles head-on bus crashes crashes creating pressure to upgrade the Pacific Highway intermingling with holiday traffic, occurred near Kempsey and especially through towns. In addition, Grafton, two months apart. work to upgrade the highway. At this The initial joint funding commitment many of the bridges constrained time, the Raymond Terrace bypass and was the first in a series of agreements efficient movement of vehicles, created In the early 1990s the NSW Taree bypass were already underway between the two governments, safety problems and were expensive Government funded a five-year (opening 1998 and 2000, respectively). culminating with the Woolgoolga to to maintain. highway improvement program and Ballina project. The joint strategy for improving the commissioned a study on the road In 1989, two catastrophic head-on bus highway needed to address local In 1997 the Pacific Highway upgrade transportation needs of the Hexham- crashes occurred near Kempsey and community needs, including changes program office opened in Grafton, Queensland coast corridor. Grafton, two months apart. Fifty-six to land use and population growth, with staff also based in Newcastle, to people were killed and many others In 1996, an agreement between the and accommodate different types of deliver on the commitment to duplicate were injured in these devastating NSW and Australian governments highway users including freight, tourist, the highway between Hexham and the crashes that impacted so many lives. was reached for a 10-year program of long-distance and local traffic. Queensland border.

12 An iconic journey Pacific Highway upgrade – By the numbers Tweed Heads Pacific Highway upgrade 1996-2020

Ballina By the numbers Broadwater Woodburn

More than More than Maclean

$15+ billion 30 Grafton invested over life of program towns and villages bypassed Glenugie

Halfway Creek

Final length of More than Woolgoolga 657km 100,000 between Hexham and direct and indirect jobs generated the Queensland border over the life of the program Nambucca Heads Macksville

Travel time cut by about More than

Kempsey 2hr 30min 40 between Hexham and individual projects Kundabung the Queensland border delivered Port Macquarie

About More than

600 9000 Taree bridges built hectares of high-value native vegetation protected through biodiversity offsets Forster

Bulahdelah

Karuah Raymond Terrace Pacific Highway upgrade – 1996-2020 13 Newcastle The sections

Oxley Port Macquarie Hexham to Highway 16 15 Port Macquarie Kew Projects delivered 1 Raymond Terrace bypass 14 Opened to traffic December 1998 2 Raymond Terrace to Karuah The upgrade between Hexham and the Opened to traffic December 2000 13 Oxley Highway at Port Macquarie was 3 Karuah bypass 12 Opened to traffic September 2004 completed to four-lane divided carriageway Taree 4 Karuah to Bulahdelah (section 1) in 2012 and consisted of 16 projects. 11 Opened to traffic December 2006 5 Karuah to Bulahdelah 10 (sections 2 and 3) 9 Opened to traffic October 2009 Nabiac 6 Bulahdelah upgrade 8 Opened to traffic June 2013 219 kilometres 126 bridges 7 Bulahdelah to Coolongolook in length Coolongolook Forster Opened to traffic October 1999 8 Coolongolook to Wang Wauk Opened to traffic July 2001 $2.2 billion 15 interchanges 9 Wang Wauk to Bundacree Creek total cost, funded by 7 Opened to traffic December 1998 the Australian and NSW governments Bulahdelah 10 Bundacree Creek to Possum Brush 17 rest areas 6 Opened to traffic November 2006 11 Taree bypass 35 minutes 5 Opened to traffic May 2000 reduced travel time 12 Taree to Coopernook 4 Opened to traffic August 2005 13 Coopernook bypass 3 Karuah Opened to traffic March 2006 2 14 Coopernook to Herons Creek Opened to traffic July 2010 1 Raymond Terrace Hexham 15 Herons Creek to Stills Road Opened to traffic September 2013 16 Herons Creek duplication Opened to traffic July 1998 14 An iconic journey Newcastle Aerial view, looking south, of the Bulahdelah upgrade in July 2013 July in upgrade Bulahdelah the of south, looking view, Aerial Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Hexham to Port Macquarie The Pacific Highway at Nabiac, built as part of the Bundacree Creek to Possum Brush project

An aerial view of the Raymond Terrace bypass, which opened to traffic in 1998

The Karuah bypass under construction 16 An iconic journey in June 2004 which opened to traffic in 2010 in traffic to opened which Coopernook to project, Herons Creek the on 2009 in underway Construction 1999 in traffic to which opened to Coolongolook project, Bulahdelah the of view Aerial opened to traffic in July 2001 July in traffic to opened The Coolongolook to Wang Wauk project Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Hexham to Port Macquarie The bridge over North Channel Manning River, 18 An iconic journey built as part of the Taree bypass after opening to traffic in December 2006 December in traffic to after opening The Karuah to Bulahdelah project 2000 in traffic to opened project Karuah to Terrace Raymond The

traffic and landscaping in January 1999 January in landscaping and traffic with completed bypass Terrace Raymond The under construction project Brush Possum to Creek Bundacree the of view Aerial Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Hexham to Port Macquarie Aerial view of the Coopernook bypass, which opened to traffic in 2006, 20 An iconic journey and the Francis Longsworth Bridge over the Landsdowne River beautiful natural landscapes through passes project This wetlands. and River Karuah the over bridge the of Construction

which opened to traffic in November 2006 November in traffic to opened which project, Brush Possum to Creek Bundacree the of part as built Nabiac at Overpass which opened to traffic in 1999 in traffic to which opened to Coolongolook project, Bulahdelah the on paving Road Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Hexham to Port Macquarie 12 Port Macquarie to 11 10

Coffs Harbour 9 Urunga

The upgrade between Port Macquarie and 8 Projects delivered 1 Sancrox interchange Coffs Harbour was completed to four-lane divided Nambucca Heads Opened to traffic November 2015 carriageway in 2018 and consisted of 12 projects. 2 Oxley Highway to Kundabung Macksville Opened to traffic in two stages – November 2017 and March 2018 Warrell 7 Creek 3 Kundabung to Kempsey Opened to traffic September 2017 Eungai 4 Kempsey bypass 145 kilometres 147 bridges Opened to traffic March 2013 in length 6 5 Fredickton to Eungai Opened to traffic May 2016 $4.5 billion 17 interchanges 5 6 Eungai duplication total cost, funded by Opened to traffic March 1999 the Australian and Frederickton 7 Warrell Creek to Nambucca Heads NSW governments Opened to traffic in two stages – 7 rest areas Kempsey 4 December 2017 and June 2018 8 Nambucca Heads to Urunga 30+ minutes Opened to traffic July 2016 reduced travel time 3 9 Raleigh deviation Opened to traffic September 1998 Kundabung 10 Bonville upgrade Opened to traffic September 2008 11 Lyons Road to Englands Road Opened to traffic May 2001 2 12 Bray Street to Arthur Street Opened to traffic August 2000 Port Macquarie

Oxley 22 An iconic journey Highway 1 Kempsey bypass project, is the longest bridge in Australia in bridge longest the is project, bypass Kempsey the of part as built Bridge, Valley Macleay the kilometres, 3.2 At Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Port Macquarie to Coffs Harbour The Raleigh deviation opened to traffic in September 1998

Looking south between Kalang and Martells Road Built as part of the Oxley Highway to Kundabung project, 24 An iconic journey on the Nambucca Heads to Urunga project in 2014 the bridge over the Hastings River is almost 600 metres long Bridge over the Nambucca River Nambucca the over Bridge being placedon the Hughes Phillip girder final the of view Aerial as part of the Oxley Highway to Kundabung project Kundabung to Highway Oxley the of part as River Hastings the over bridge the on 2016 in underway Work in Coffs Harbour opened in August 2000 August in opened Harbour in Coffs project Street Arthur to Street Bray The Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific December 2017 in opening to prior Bridge The Hughes Phillip completed

25

Port Macquarie to Coffs Harbour Pouring concrete for the bridge over the Nambucca River Earthwork being carried out in Newry State Forest during 2014 in July 2016 on the Warrell Creek to Nambucca Heads project as part of the Nambucca Heads to Urunga project

The new section of highway south of Urunga, built as part of the Nambucca Heads to Urunga project

The Frederickton to Eungai upgrade in July 2016. 26 An iconic journey The project opened in May that year

Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific of the section of highway near Valla near highway of of the section Aerial view, looking north, north, looking view, Aerial

27

Port Macquarie to Coffs Harbour Looking south towards the interchange at , built as part of the Raleigh deviation

Bridge piling south of the Kalang River in 2014 on the Nambucca Heads to Urunga project

Construction activity on the Warrell Creek to Nambucca Heads project, 28 An iconic journey looking north at Cockburns Lane The Bonville upgrade opened to traffic in September 2008 September in traffic to opened upgrade Bonville The looking north from Bald Hill in July 2015 July in Hill Bald from looking north pad bridge Creek Warrell The Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific Aerial view of the Clybucca rest area, Clybucca rest area, the of view Aerial Frederickton to Eungai project Frederickton to Eungai built as part of the the of part as built

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Port Macquarie to Coffs Harbour Ballina Coffs Harbour Casino 6 Broadwater to Ballina Woodburn Evans Head The upgrade between Coffs Harbour and Ballina Projects delivered 1 Korora Hill duplication was completed to four-lane divided carriageway Opened to traffic in December 1997 in 2020 and consisted of six projects. 2 Sapphire to Woolgoolga 5 Opened to traffic in July 2014 3 Woolgoola to Ballina Maclean Opened to traffic in stages: - 2017 (26km) - 2019 (8km) 204 kilometres 198 bridges - 2020 (121km) in length 4 Glenugie upgrade Opened to traffic September 2012 5 Devils Pulpit billion interchanges $6 17 Opened to traffic in March 2014 total cost, funded by Grafton the Australian and 6 Pimlico to Teven Opened to traffic in May 2016 NSW governments 7 rest areas 4 30+ minutes reduced travel time Halfway Creek

3

Woolgoolga

2 30 An iconic journey 1 Broadwater of bypass Highway Pacific The Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Coffs Harbour to Ballina The Sapphire to Woolgoolga project opened to traffic in 2014

32 An iconic journey opening to traffic in September 2020 September in traffic to opening after interchange Maclean The

after opening to traffic in March 2020 March in traffic to opening after on the Woolgoolga to project Ballina Maclean at highway of section The Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific Iluka interchange in July 2020 July in Iluka interchange Aerial view of the the of view Aerial

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Coffs Harbour to Ballina Bridges built over Emigrant Creek, south of Ballina, in July 2019

Aerial view of the bridges over the The new bridge over the 34 An iconic journey Coldstream River in May 2020 Richmond River at Broadwater New bridge over the Clarence River at Harwood at River Clarence the over bridge New Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Coffs Harbour to Ballina View of Tyndale, looking south, after opening in May 2020

The Pine Brush rest areas in May 2020, built as part of the Woolgoola to Ballina project

Aerial view of work underway on Dirty Creek Range in 2015 on the 36 An iconic journey Woolgoola to Halfway Creek section

Halfway Creek project in July 2016 project Creek Halfway Woolgoolga to the on underway Work construction in August 2013 under project Pulpit Devils The at Sandy Beach, April 2014 April Sandy Beach, at interchange north Emerald Beach the to south Looking Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Coffs Harbour to Ballina Tweed 11 Heads Ballina to the 10 Chinderah Queensland border 9

The upgrade between Ballina and the 8 Projects delivered 1 Ballina bypass Queensland border was completed to four‑lane Opened to traffic in May 2012 divided carriageway in 2015 and consisted of 2 Tintenbar to Ewingsdale Opened to traffic in December 2015 11 projects. 3 Ewingsdale interchange Opened to traffic in December 2000 Yelgun 4 Ewingsdale to Tyagrah 7 Opened to traffic in October 1998 5 Tandys Lane realignment Brunswick Heads 91 kilometres in length 119 bridges Opened to traffic in December 2001 6 6 Brunswick Heads bypass (stage one) Opened to traffic on June 1998 $2.7 billion total cost, 15 interchanges funded by the Australian 5 7 Brunswick Heads to Yelgun and NSW governments Opened to traffic in July 2007 (this includes the $543 million 4 8 Yelgun to Chinderah Tugun bypass, which was 6 rest areas Ewingsdale Opened to traffic in August 2002 Byron Bay funded by the Queensland and 9 Chinderah bypass Australian governments) 3 Opened to traffic in November 1996 10 Banora Point upgrade Opened to traffic in April 2012 45 minutes reduced travel time 11 Tugun bypass 2 Opened to traffic in June 2008

Tintenbar

Lismore Ballina 1

38 An iconic journey The Ballina bypass opened to traffic in August 2012 August in traffic to opened bypass Ballina The Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Ballina to the Queensland border The Environ Road overpass, built as part of the Yelgun to Chinderah project

Work outside the in January 2014

Bridge work on the Tintenbar to Ewingsdale project 40 An iconic journey looking south over Byron Creek in October 2013 Minor and Emigrant creeks in 2015 in creeks Emigrant and Minor over bridges twin new of view Aerial St Helena tunnel in January 2014 January in tunnel St Helena the at through Breaking project Yelgun to Heads the Brunswick of part as built at Billinudgel, overpass the using Cyclists Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Ballina to the Queensland border View of Mount Warning and the Brunswick Heads to Yelgun project 42 An iconic journey in July 2007 after opening to traffic in July 2007 July in traffic to opening after project Yelgun to Heads Brunswick The in December 2011 in December upgrade Point Banora on the cutting main the on Work on the Banora Point project in April 2012 April in project Point Banora on the of theOpening mainline southbound Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Ballina to the Queensland border Aerial view of the northern section Steel reinforcements ready and in place of the Ballina bypass, for road pavement along the southbound which opened to traffic in May 2012 carriageway at Bangalow in December 2014

The Cudgen tunnel, built as part of the Yelgun to Chinderah project

The Tugun bypass tunnel 44 An iconic journey opened to traffic in 2008 during the community day in September 2012 September in day community during the upgrade Point Banoria the of view Aerial Pacific Highway upgrade – 1996-2020 – upgrade Highway Pacific

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Ballina to the Queensland border Saving lives was driving force behind the upgrade from day one

The team delivering the upgrade program never lost sight of the main objective – making the Pacific Highway safer for the millions of people who drive it each year.

While only one-third of people live in improvements to the existing highway, regional NSW, two-thirds of all fatal led to a substantial reduction in fatal crashes occur in regional areas. and injury crashes. This was achieved A safer highway despite an increase in the volume The fatality rate in regional NSW is Fatalities on the Pacific Highway between Hexham and the Queensland border of traffic using the highway in the more than four times higher than in since the start of the upgrade program in 1996 corresponding period. metropolitan areas. Road crashes, 60 injuries and deaths impact whole As the graph shows, fatalities on the communities, and negatively affect Pacific Highway have significantly reduced since the upgrade began in 1996. many – those involved in the crash, 50 their family and friends, rescue and With the entire route now upgraded to emergency services workers, doctors four-lane divided highway, it is expected and nurses, and everyone who lives that over a 30-year period, 8039 40 or works on or near the highway. crashes, 4218 injuries and 3255 non- When the upgrade program started in injury accidents will be avoided and 1996, more than 40 people were dying 565 lives saved. 30 on the Pacific Highway each year. Achieving a more than 70 per cent In the years immediately after the upgrade reduction in fatalities because of the 20 started, there were years when more than divided road is a statistic of immense 50 people died on the highway. importance for the team delivering the Pacific Highway upgrade program. It took time, but as the upgrade progressed 10 While the safety improvements since and more and more sections of dual-lane 1996 have been significant, every life highway opened to traffic, the number lost on our roads is one too many. It is and severity of crashes began to fall. 0 for this reason Transport for NSW will 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 Since 1996 the Pacific Highway upgrade, continue to work towards the goal of along with a number of interim safety zero fatalities.

46 An iconic journey Aerial view of the Frederickton to Eungai project, which bypassed the site of the Clybucca bus brash

INSET: The Clybucca bus crash in 1989 claimed the lives of 35 people

PHOTO: News Corp

Pacific Highway upgrade – 1996-2020 47 Upgrade leaves behind legacy of innovation

For more than two decades the Pacific Highway program office has found ways to overcome a unique set of challenges and constraints to deliver a world-class highway.

The highway upgrade was delivered the opportunity to try new ideas and by an experienced, dedicated and develop them into the new benchmark. innovative team. While the office and The Pacific Highway upgrade program upgrade staff were based primarily out led the way in project delivery at of Grafton, the team comprised talented Transport for NSW (TfNSW). A number people up and down the length of the of processes and procedures that upgrade from Hexham to the border. started on the program were later rolled In delivering the program, the upgrade out across other TfNSW programs. team developed a mindset of innovation Some of these innovations included: and achievement. • Internal alliances Not singularly focused on time and • Construction management plan cost, the Pacific Highway upgrade team templates consistently looked to provide public • Bridge design and construction value in the delivery of each project. This focus on public value meant the • Design guidelines. upgrade team never lost sight of the fact This is not to mention the numerous the upgraded Pacific Highway needed innovations in the areas of environment to service the needs of the travelling and safety. public, while also achieving transport efficiencies, ensuring ecological The innovation achieved by the upgrade sustainability and meeting the needs team was made possible by the highest of the communities who live alongside level of executive support to make the highway. decisions about the best way to deliver projects with a range of challenges. Placing girders for the bridge The long duration and pipeline of projects over the Clarence River at Harwood delivered along the Pacific Highway corridor allowed continuous learning and

48 An iconic journey One of the successes of the program The long duration and was the willingness of industry and our pipeline of projects delivery partners to roll up their sleeves delivered along the Pacific and work collaboratively with the team on all elements of project delivery Highway corridor allowed through early planning, construction, continuous learning and the stakeholder engagement, environmental opportunity to try new ideas compliance and safety. and develop them into the The delivery of the Pacific Highway new benchmark upgrade program was paralleled For example, the program delivered the by increasing sophistication in the first elevated roundabout interchange contractual relationships and has fostered in the Southern Hemisphere and the a growing appetite and appreciation for longest road bridge in Australia at partnership and innovation (see fact box). Kempsey, which spans 3.2 kilometres. Relationships were at the core of each Soft soils have also caused many contract model, relationships built on challenges and required engineering respect, trust, collaboration and an innovation to overcome. Highway and awareness of the skills and expertise engineering standards changed over available to TfNSW from private sector the 25 years of the upgrade program, infrastructure providers. A program of requiring flexibility and adaptability on this scale and ambition generated an the part of the upgrade team. Aerial view of soft soil work underway on the array of engineering challenges. Woolgoolga to Ballina project in February 2016

Innovative partnerships The following contract models were used to deliver the Pacific Highway:

Construct only: the traditional Design, construct, maintain: Alliance: collaborative Design and construct: Delivery Partner: used to way of road construction. structured like a standard arrangements to deliver a road used for higher cost and deliver the London Olympics, TfNSW provides a detailed design and construct infrastructure project with more complex projects. this model was used to deliver design and tenders are invited arrangement except the decisions made on a ‘best for The contractor is engaged the 155km Woolgoolga to for a separate construct-only contractor is also responsible project’ basis. An Alliance is to design and construct the Ballina upgrade. The model contract. The majority of for post-construction used for projects with high project work based on a design involved embedding TfNSW the projects in the Hexham maintenance for a designated risks or those difficult to scope brief supplied by TfNSW. This staff in the integrated delivery to Port Macquarie section time period (usually 10 years). and are technically challenging. model was adopted following team. The contractor, on behalf were built by construct The first DCM project The first project on the Pacific collaboration with industry. of TfNSW, oversaw delivery only contracts. contracted out by TfNSW Highway to use an Alliance for Sapphire to Woolgoolga was and procured contracts to was the Bulahdelah to delivery was Coopernook to the first project delivered directly engage skilled sub- Coolongolook project. Moorlands in 2007. under this model. contractors and suppliers.

Pacific Highway upgrade – 1996-2020 49 Caring for the environment came naturally

The Pacific Highway traverses some of the most diverse ecological areas on the east coast and for this reason, the environment was front of mind for the team delivering the upgrade.

Given these important environmental functionality for native fauna movement community understanding on the considerations, one of the key objectives • Installing artificial hollows within ecology of threatened plant species. of the upgrade program was to existing trees manage the delivery of this vital piece Continual learning of infrastructure with ecologically • Modifying bridge and culvert designs sustainable development principles. to create habitat for threatened The environment team, in collaboration microbat species with colleagues from the upgrade To meet this challenge, the team • Implementing long life (>30 year) program office, focused on building adopted an ‘avoid, minimise and mitigate’ design life nest boxes in habitat relationships with contractors and strategy for managing environmental adjacent to the Pacific Highway stakeholders to ensure the value of the impacts. During the almost quarter environment function was understood, • Repurposing tree root balls salvaged century of the upgrade program, more and everyone worked together to from clearing to be used in waterway than 100 different threatened species deliver outcomes that minimised our rehabilitation projects in conjunction were identified, and the project team environmental impacts, saved money with local Landcare groups and the developed and implemented a vast array and enhanced the reputation of TfNSW. of innovative design and management National Parks and Wildlife Service With the successful delivery of each measures to build a highway through • Salvaging and relocating native project, the team developed robust diverse ecological areas. beehives prior to clearing processes and procedures that helped The project team always looked for ways • Implementing innovative erosion deliver superior outcomes as the to improve designs and management and sediment controls, which were program progressed. measures to minimise environmental recognised as industry best practice. For example, the construction impacts, including: For close to two decades the project management plan for the Woolgoolga • Preserving the native orchid, team carried out translocation of to Ballina project was approved in only rhizanthella slateri, on the threatened flora prior to any mainline three months by the Department of Bulahdelah upgrade clearing. This translocation work Planning, Industry and Environment – A rufous bettong found on a substantially contributed to the scientific almost unheard of in the industry for • Modifying culvert designs to improve biodiversity offset property knowledge and improved scientific a project of its size and complexity.

50 An iconic journey The culture of adding value and working edge of animal connectivity measures together helped the Pacific Highway in Australia. Coastal emus found on a upgrade program win 25 external biodiversity offset property Along the route, ‘soft scour’ treatments, awards from best practice in ecology incorporating native vegetation, have and transportation through to numerous been installed at culverts to encourage awards in environmental management the movement of animals under the and sustainability. highway. Elevated animal crossings have been installed and streams re-formed Staying connected and landscaped for fish passage.

Animal protection was also an In the north, the protection of important consideration. local koala populations was a key challenge. The Ballina Koala Plan was Throughout the life of the program, prepared as part of the Woolgoolga fauna connectivity structures were built to Ballina project in response to better and monitored. The fauna structures understand the potential impacts on protect wildlife, allow animals to safely the koala population. The plan outlined cross over and under the highway, and appropriate mitigation measures, lets them move freely through habitats such as ‘closed fencing’ in conjunction to access food, water and mates. with koala grids along the highway, Monitoring our animal connectivity integrated predator control program structures for more than 20 years and the planting of 130 hectares of koala provided evidence they do work, habitat next to the highway alignment with TfNSW designs at the leading on previously cleared land.

Fauna land bridge built as part of the Bonville upgrade, south of Coffs Harbour

Pacific Highway upgrade – 1996-2020 51 Biodiversity offsets habitat in meeting its biodiversity offset obligations. TfNSW converted previously The biodiversity offset program adopted degraded cane land into what is now for the upgrade program has also been a very high conservation habitat, including success story. the creation of the Teven Wetlands, Offset properties provide habitat for which supports bird diversity rivalling a huge range of threatened animals, the Macquarie Marshes. including but not limited to koalas, Under the offset program TfNSW spotted-tail quolls, giant-barred frogs, successfully secured critically wallum sedge frogs, green-thighed endangered ecological communities, frogs, squirrel gliders, yellow–belly such as littoral rainforest. gliders, glossy black cockatoos, oxleyan pygmy perch and the coastal On the Woolgoolga to Ballina project, emu population. the 3600-hectare biodiversity offset was the largest offset program ever The Pacific Highway upgrade program delivered by TfNSW and one of the has secured more than 9000 hectares largest in NSW. of high-value native conservation

A combined fauna culvert

A giant barred frog found on one of the upgrade program's biodiversity offset properties

Fast facts

• More than 480km of fauna • More than 9000 hectares fencing installed of high-value native vegetation protected through • More than 300 fauna biodiversity offsets. connectivity structures built • More than 20 years of • More than 600 nest boxes ecological monitoring undertaken, installed capturing learnings and applying to new projects.

52 An iconic journey Large sections of the highway have been built in sensitive environments

Pacific Highway upgrade – 1996-2020 53 An upgrade built for the people, by the people

At its core, the Pacific Highway upgrade program was delivered for the community - local communities along the highway, as well as the wider community in NSW and across Australia who use the highway to travel for work, education or leisure.

Ensuring the community was heavily While almost everyone in the community involved in the delivery of the program supported building a safer and more was one of the key tasks of the efficient highway, project teams often had delivery team. to balance competing priorities among different pockets of the community when Communities were involved in the it came to route selection and access. program every step of the way, from route identification and selection, to Route selection was a particularly operation of new sections of highway. challenging element of the upgrade. Project teams spent a significant amount Community consultation was a vital Community engagement was a key feature of every project delivered on the of time working with all the various source of local knowledge and provided Pacific Highway upgrade stakeholders, internal and external, an educational role when choosing during the route selection process. To meet this challenge, the project team One example of this commitment to options for projects. It often helped Teams worked closely with landowners embraced the concept of public value. delivering public value and considering project teams better understand how to understand their concerns and aim This proved to be a delicate balancing the needs of the community in decision people may be affected by proposals to find solutions to help them when a act at times. Where possible, decisions making was the option to build tunnels and the conflicting views of the route option passed through or near were made taking into consideration the for the new highway at St Helena, community. The challenge was trying their property. best outcome for the community and instead of duplicating the existing to manage community expectations the project. highway alignment across St Helena Hill. with delivery.

54 An iconic journey Thousands of people took the opportunity to talk on the Kempsey bypass bridge in 2013 Lions Club volunteers at the Banora Point community day prior to it opening to traffic During the development of the route benefits by shortening the length of upgrade program started, but in a very such as face-to-face community alignment and environmental impact the highway, reducing the grade to a short time changed the way the project information sessions, were utilised on all assessment for the section of highway maximum of four per cent, and removing teams did business. For example, the projects to keep communities engaged between Bangalow and St Helena, all at-grade access and egress to Bulahdelah to Coolongolook project, and informed. Of course, towards the the community expressed significant the highway. which opened in 1999, was the first on latter stages of the upgrade program concerns about the upgraded highway the Pacific Highway to use email as the social media played a critical role in Of course route selection was following the existing alignment over primary method of communication. community engagement. sometimes just the start of St Helena Hill due to a history of slope community interaction. Technology advanced rapidly during Celebrating the opening of new sections instability and noise from trucks using the life of the upgrade program and of road has been one of the highlights compression braking due to the steep Communities along the route were often changed the way TfNSW interacts with of the Pacific Highway program. These eight per cent grade of the alignment. heavily impacted during construction the community. While these changes celebrations, often in the form of a As a result of these concerns, TfNSW and working closely with those people, proved to be highly effective for community day during which members revisited the route alignment and as well as those with a strong interest motivating participation, the upgrade of the public can walk on the new developed an alternative route that in projects, was an important part team still had to cater for those people alignment, have been TfNSW’s way of included twin tunnels through St Helena of delivery. without access to technology. For this thanking communities for their support Hill. While this route was more expensive reason a mix of technology-based and and patience during projects. to build, it returned good economic Electronic correspondence was new to the workforce when the Pacific Highway conventional engagement activities,

Pacific Highway upgrade – 1996-2020 55 Connection to Country at heart of upgrade

The Aboriginal communities of the North Coast played a key part in the development, delivery and successful completion of the Pacific Highway upgrade program.

Aboriginal engagement in cultural At the peak of the 155-kilometre heritage impact assessment and Woolgoolga to Ballina project, 281 participation in the delivery of (or nine per cent) of the 3300 strong construction contracts was an integral project workforce identified as an element of successfully delivering the Aboriginal person. Pacific Highway upgrade program. In addition, eight per cent of the Between Hexham and the Queensland Aboriginal or Torres Strait Islander border the Pacific Highway passes workers had cultural associations through the traditional estate of at least with the Gumbaynggirr, Yaegl and seven Aboriginal language groups. Over Bundjalung people. almost a quarter of a century we have Aboriginal people performed a broad worked with Aboriginal communities range of roles on the Woolgoola to during the delivery of each project to Ballina project, paving the way for a ensure impacts on Aboriginal cultural new generation of skilled workers and heritage were minimised. business owners and exceeded targets The Pacific Highway upgrade program Aboriginal dancers perform at a NAIDOC Week celebration at the Pacific Highway office set under the NSW Government’s was committed to supporting in Grafton Aboriginal Participation in Construction employment of Aboriginal people. (APiC) policy. TfNSW recognises the benefits workers. Aboriginal participation in the to complex engineering and cultural The Aboriginal community has worked employment brings to an individual project workforce approached 20 per landscape management issues. The with Aboriginal businesses and TfNSW and the flow-on effect it can have on cent on some of the highway projects two-way sharing of knowledge helped to interpret and present Aboriginal their family and their community. The delivered during the life of the program. to build the cultural capability of TfNSW cultural knowledge along the Pacific Pacific Highway program office and staff, ensure Aboriginal interests were There are many examples over the Highway to enrich the travelling its contractors worked closely with respected and further developed course of the upgrade program where experience for all highway users. institutions like North Coast TAFE Aboriginal community experience in TfNSW worked closely with Aboriginal to attract, train and place Aboriginal civil construction. communities to develop solutions

56 An iconic journey “I am proud to have worked on an iconic project amongst three proud Indigenous nations. It was great to work with local communities and people I have known for many years.”

Gamilaraay man Kurt Scheuermann

Kurt Scheuermann worked as a safety adviser on the Woolgoolga to Ballina upgrade

Pacific Highway upgrade – 1996-2020 57 It was an honour to work on so many Pacific Highway projects for more than a decade. An economic boost – The upgrade has impacted so many people – from families who have lost loved ones on the old highway to local communities that don’t have B-doubles and tourist traffic on their now and into the future local roads. And then there's the people who came together to make it happen. Love it.

Matt Howard, supervisor and surveillance officer for 12 years on various projects The Pacific Highway provided significant economic benefit to regional communities between Hexham and the Queensland border.

The long-term nature of the Pacific Highway upgrade program and the scale of work required has been a great opportunity for local people to find fulfilling employment that provides professional development and the accumulation of skills.

Since 1996 it is estimated more than 100,000 direct and indirect jobs were generated across the more than 40 projects delivered between Hexham and the Queensland border.

On the Woolgoolga to Ballina project alone at the peak of construction, more than 3000 people were working directly on the 155-kilometre project, injecting millions of dollars into local economies.

The large workforces needed to deliver the upgrade also attracted new people to regional communities, with evidence showing many of those people chose to stay on after relocating to work on the highway program. Building the noise wall for the northbound off‑ramp on the Banora Point project

58 An iconic journey The future is bright access from the region to Sydney Tourism on the North Coast is worth and Brisbane. more than $3.4 billion annually and While the creation of jobs generated supports about one in three jobs in short-term boosts for regional Reducing travel times on the highway the region. The upgrade of the Pacific communities, there are also multiple allows more people to commute Highway supports the continued long-term benefits associated with to and from regional towns to the growth of the tourism industry, which the upgrade. regional cities for employment and will continue to make a significant education opportunities. This will help During a 50-year period from 1994 to contribution to jobs growth as the accommodate projected population and 2044, business output is estimated to number of visitors to the region housing growth and a support a range increase by $9.07 billion, and Gross continues to increase. of employment centres across the region. State Product is estimated to increase by $3.55 billion.

But it’s the wider economic benefits that will really help regional communities. The completed Pacific Highway upgrade program provides a route that supports economic development through consistency with regional strategies and progressive completion of key links.

The completion of the Pacific Highway upgrade will make it easier for residents to get to jobs, for visitors to access the At the peak of construction more than 3000 people wide range of tourist activities and for were working on the Woolgoolga to Ballina project industries to expand through better

At the peak of construction on the The Pacific Highway upgrade program Woolgoolga to Ballina project there were generated more than 40,000 direct more than 1000 pieces of machinery onsite jobs over the life of the program

Pacific Highway upgrade – 1996-2020 59 Opportunity knocks for bypassed towns

Local communities that once had to live with highway traffic have been rejuvenated by the upgrade.

Since the start of the highway upgrade environmental amenity for residents from program in 1996 up to completion in reduced traffic volumes on local roads. 2020, more than 30 towns and villages have been bypassed. Bulahdelah In many instances the realignment of the Bulahdelah is well-positioned as highway to bypass towns has improved a convenient fatigue stop and the the appeal of towns for visitors, especially beautification of the town helped in the long term. In many cases the attract customers back, fuelling growth reduction in through traffic has made in the town. In the nine months post- bypassed towns more pleasant places to opening of the bypass in mid-2013, there live in and visit. While there is no doubt was a 7.7 per cent increase in visitors some businesses that relied primarily on to Bulahdelah. passing highway traffic were impacted, particularly in the short-term, generally Kempsey towns and villages have seized on the new long-term economic opportunities Until Kempsey was bypassed in 2013, presented by the upgrade. the Pacific Highway was a thoroughfare that cut the town in half — bringing The Pacific Highway upgrade team tourists and trucks, but discouraging worked closely with local councils and locals. However, now the Kempsey CBD businesses throughout the life of the has become a retail hub after significant program to prepare towns and villages gentrification. A study by Dr Bruno for bypasses and to mitigate the short- Parolin found that despite significant term impacts. fear amongst the business community Town bypasses have been found to before the bypass, between 2013 and generally result in positive social impacts 2017 there was an increase of 22% in jobs across all businesses. such as better quality of life and A bypassed town sign being installed for Nambucca Heads

60 An iconic journey The Kempsey CBD has been revitalised since the bypass opened in 2013

Pacific Highway upgrade – 1996-2020 61 Highway upgrade a game changer for movement of freight

Enabling the safe, productive and sustainable movement of freight was an important reason for building a world-class, four-lane highway between Hexham and the Queensland border.

Prior to the mid-1990s, this popular of goods best suited to specific regions, route for travellers and freight passed and allowing larger scale production through more than 30 towns and than would otherwise occur. villages and meandered through hilly terrain, preventing some freight from using the route. Prior to the mid-1990s, The freight industry is the lifeblood of this popular route for the NSW economy – worth $66 billion to travellers and freight passed the state economy. From big businesses through more than 30 towns to farmers, retailers to consumers, we and villages and meandered all rely on our goods getting to us in a through hilly terrain, safe and efficient manner. At the most preventing some freight basic level, freight determines the availability of, and the prices we pay, for from using the route. goods. It helps to create a worldwide market for NSW products by facilitating By providing reduced travel times the transport of goods from the place (around three hours in total for freight of production to the place where they vehicles), increased and more consistent are consumed, including assembly speeds and lower grades, the Pacific of raw materials and distribution of Highway upgrade program has reduced finished goods. costs to the economy of travel time, Freight is particularly critical to the fuel costs, vehicle costs and costs to business while significantly improving A truck navigates the Pacific Highway, economic development of regional and 13 kilometres north of Nambucca, in 1959 rural NSW, by supporting the production road safety.

62 An iconic journey “The dual carriageway means there is plenty of room for higher capacity vehicles, making it safer for all road users. It also means we can carry more goods in less time to get where they need to be, including supermarket shelves.”

Jim Pearson, owner of Jim Pearson Transport

Freight travelling south on the Pacific Highway at Glenugie

NSW plays a key role in the movement movement of freight in NSW even more national transport route is able to meet and safety benefits for the community of freight across Australia, with the road critical. In 2016, the Pacific Highway the future task. and industry. network alone carrying over 60 per cent carried more than 12 million tonnes With the completion of the Pacific This means fewer vehicles are required of the total NSW freight task. of freight and is forecast to reach Highway upgrade, modern Higher to carry the same amount of freight, 17 million tonnes in 2036 and increase NSW is also the connection for freight Productivity Vehicles will be able reducing transportation costs and to 23 tonnes by 2056, which is almost transport travelling to Brisbane, to travel along the route, bringing reducing the number of heavy vehicles double current volumes. The upgraded Adelaide and Melbourne, making the significant productivity, environmental on the road. Pacific Highway ensures that this key

Pacific Highway upgrade – 1996-2020 63 Keeping workers safe has been no accident

While the safety of the people building the Pacific Highway upgrade was always as important as the people driving the road, the approach changed dramatically during the delivery of the program.

The Pacific Highway upgrade was Robust reporting Separate Yourself program Embracing technology carried out during significant change in The upgrade program integrated lead The Separate Yourself program was Trials of technology, including variable work health and safety in NSW, including indicators into contractor performance introduced to manage the interface speed limit signs and portable traffic the passing of the OHS Act in 2000, the measures within the WHS Traffic Lights between people, machinery and vehicles lights, reduced the exposure of traffic WHS Act in 2011 and an update to the reporting program. By incorporating on Pacific Highway sites. The program controllers to live traffic, which is a WHS Regulation in 2017. hazard reporting, consultation and brought a risk management approach frequent high-risk activity on upgrade Transport for NSW (TfNSW) and its leadership activities as measures, the and consistency to one of the highest projects. There were also trials of traffic industry partners rose to this challenge Pacific Highway upgrade projects brought risk operations in civil infrastructure. management initiatives for working and completed the upgrade program with a focus on prevention and behaviours The program was adopted by a number next to live traffic, including yellow an outstanding health and safety record. identified in research as being key to of contractors as their own standard line marking and a traffic control developing better safety performance. and ensured consistency was achieved centre. Providing clear delineation and This was achieved by working across projects. managing the impact of upgrade work collaboratively with contractors to Workplace Health and to the travelling public were the focus of establish standards and ways of these two innovations. working that incorporated innovation Safety forums and improvements in machinery, These twice-yearly forums provided an equipment, systems and technology. opportunity for contractors and TfNSW Ideas and strategies were built over to communicate and collaborate across The Pacific Highway upgrade time, with lessons from one project all Pacific Highway upgrade projects. taken to the next through a continuous The forums allowed us to share lessons was carried out during improvement approach. and innovation so the development of significant change in work better safety practice was expedited Following are some of the innovations and improved. Many of the innovations and improvements the Pacific Highway health and safety in NSW. were published in the six-monthly team embraced during delivery of highway upgrade reports. the program.

64 An iconic journey How times have changed Workplace health and safety has come a long way in a relatively short period of time in terms of how TfNSW builds roads. A visible example is the type of personal protective equipment (PPE) workers are required to use, as demonstrated by these photos taken less than 30 years apart. The top photo was taken in 1990 prior to the start of the Pacific Highway duplication program. It shows construction of the Pacific Highway Swan Creek deviation, north of Grafton, with workers wearing little or no PPE. The bottom photo was taken in 2017 during construction of the Woolgoolga to Ballina project, with workers in full PPE including hard hats, steel cap boots, long sleeves and pants, gloves and safety glasses.

Pacific Highway upgrade – 1996-2020 65 Then and now Then

66 An iconic journey Now

These photos, taken more than 60 years apart, demonstrate how far the Pacific Highway has come over the years. The photo on the opposite page shows the Pacific Highway (now Hinterland Way) in July 1947 as it wraps around St Helena Hill, looking north towards Byron Bay. The photo on this page shows the St Helena tunnel in February 2018, looking south. The old highway, where the 1947 photo was taken, can be seen to the right of the tunnels.

Pacific Highway upgrade – 1996-2020 67 20.437 ISBN: 978-1-922463-51-7