Coffs Harbour Bypass .

The Coffs Harbour Bypass features a 14-kilometre realignment of the Pacific Highway around Coffs Harbour, incorporating three twin-tube tunnels excavated through the prominent ridges of Roberts Hill, Shepherds Lane and Gately’s Road. The works were delivered by the Ferrovial Gamuda Joint Venture as principal contractor. The tunnels will each consist of two traffic lanes plus a cycle lane in each direction and required hard-rock excavation followed by full structural lining and waterproofing systems.

Direct Inject mobilised at short notice to support injection crews already on site in the delivery of a specialised polyurethane injection program to address widespread but low-volume groundwater ingress within the shotcrete-lined tunnels. The collective injection works enabled a spray-applied waterproof membrane to be installed by a follow-on contractor to a high standard, and ensured the principal contractor could achieve the projects strict groundwater inflow performance criteria prior to advancing the final lining work.

Works were undertaken across day and night shifts within active tunnel environments, operating in close proximity to other injection crews and primary lining preparation teams. Installation of the sprayed waterproofing membrane followed closely behind, requiring continual coordination to ensure sealing activities stayed ahead of downstream works. Regular progress checks and flexible sequencing were essential to maintain access and support the principal contractor’s program requirements