Piling rigs start work on bridge foundations for Coffs Harbour Bypass

Construction work on Coffs Harbour’s $2.2 billion highway bypass has entered a new phase, and it’s going quickly but ever so quietly compared to other projects. Here’s why.

Progress on the long awaited Coffs Harbour Bypass continues at pace, with piling work now underway to create solid foundations for the 17 bridges required.

While much of the focus and controversy in the bypass planning phase was whether to incorporate tunnels or just open cuttings, the bridge work is significant.

Two piling rigs are now onsite as work starts on bridges for the Englands Rd and Korora Hill interchanges.

The project team will build 42 piles in the Englands Rd (Old Bunnings) area, and 29 for the northern interchange.

Transport for NSW North Region director Anna Zycki said the construction team would build more than 300 bridge piles across the alignment, with each pile taking about eight hours to complete.

Transport for NSW North Region director Anna Zycki. Picture: Chris Knight

“Bored piling for the bridges at these interchanges will be carried out weekdays from 7am to 6pm and Saturdays from 8am to 1pm and will take about two months to complete,” Ms Zycki said.

The overall bridge piling work across the bypass corridor is expected to continue into 2026.

The Coffs Bypass site office off North Boambee Rd. Picture: Chris Knight

“The work will include building pads on which the piling rigs will sit, drilling through soil and rock to form pile holes, and installing steel reinforcement cages into the holes,” Ms Zycki said.

“We’ll then pour concrete into the holes to build the piles and, when the concrete is set, use jackhammers to remove any excess from the overpour.”

Mayor Paul Amos is working to make sure Coffs Harbour remains an enticing stop for tourists after the city is bypassed.

The $2.2 billion Coffs Bypass project will use a bored piling technique which is far quieter than driven piles which were used for the Phillip Hughes Bridge at Macksville.

“Bored piling is much quieter and less disruptive than driven piles as they don’t require hammering, but there will still be moderate and consistent noise from the piling rig as it drills through the soil and rock,” Ms Zycki said.

“Towards the end of the digging operation there will be louder clangs when material is removed from the rig’s drill piece.

“Plant and equipment will be positioned as far as possible from neighbours and respite periods may be scheduled, where required.”