Location

Palmview, Queensland

Client

Department of Transport and Main Roads

Sector

Transport 

  • Roads

Duration

 2016 – 2021

Contract value

$800 – 850 million 

Bruce Highway Upgrade: Caloundra Road to Sunshine Motorway

Fast facts

21

new bridges

1st

Diverging Diamond Interchange (DDI) in Australia

63,000 vpd

vehicles per day through the site

6 - hectares

of Beerwah State Forest vegetation saved due to innovative DDI design

50km

of new conduits and pits for electrical and ITS works

9km

of new dedicated shared pathways

About

The D&C Bruce Highway Upgrade (CR2SM) is a $932M highway improvement project which provides safer and smoother journeys for road users through the creation of additional 110km/hr highway lanes and extensive local road upgrades. The crowning jewel of the upgrade is Australia’s first Diverging Diamond Interchange (DDI) which required highly complex construction sequencing, temporary works and traffic management.

As an Australian-first, getting design right was crucial for ensuring the DDI was intuitive for road users. By adopting international learnings and transforming these into design innovations – Australia’s first operational DDI was successfully designed and constructed, opening in its final configuration in December 2020.

“As a local resident I wish to express my grateful thanks for the now completed road works on the Bruce Highway. It is a magnificent engineering achievement that will improve both safety and useability for all road users. The way the works were managed is as good as I have ever experienced, the quality of the result exceptional and the attention paid to minimising inconvenience to users and residents quite extraordinary…”

 Local resident, 01/10/21 

In addition to the DDI, and to support the growth of the Sunshine Coast region, the Fulton Hogan Seymour Whyte Joint Venture (FHSW JV) provided vital infrastructure including:

  • 21 bridges (12 over waterways) and 2 underpasses with 5,108lm of cast-in-place bored piles
  • 15km of local roads widened, upgraded and/or newly constructed
  • 8km of new multilane smart motorway
  • 9km of active transport infrastructure
  • Water and sewer relocations via traditional and various trenchless techniques including a 900m long 900mm dia HDD which saved clearing old-growth forest
  • 142,0000m3 asphalt pavements
  • 100Ha of landscaping and revegetation plus 5 fauna crossings

The team had many hurdles to overcome during the 52-month construction period: latent contamination issues; extraordinary inclement weather with over 300 lost workdays caused by ~8.8m of rainfall; a constrained footprint with high traffic volumes which experience a 14% increase during construction; interface with some ~2500 stakeholders; and of course COVID-19. Despite these challenges the team optimised construction sequencing which provided better program resilience through delinking critical activities, reducing risk. Working collaboratively with TMR, the team increased productivity, reduced rework and provided excellent outcomes for all stakeholders.

This project is more than just hard engineering and infrastructure – it brought significant innovation to the civil infrastructure industry with the engineering ingenuity of the DDI and award-winning environmental solutions – with these lessons shared with home organisations, TMR and industry partners. Importantly, this project provides greater safety for transport customers serving one of the fastest growing regions in Queensland and critical upgrades for Australian freight.  The JV D&C teams truly exemplified the behaviours of a collaborative contract – ensuring engineering excellence every step of the way.

“It is staggering how big the effort is when you step back and sum up all the moving parts that make up the project team. It is like a crafted Swiss watch – every cog and spring is brought to bear on making time move forward. Well-deserved pat on the back for all involved.”

Trevor Land, TMR Project Director, 25/09/20

Project gallery

Slide Title

Slide 1

Slide 2

Slide 3

Slide 4

Slide 5

Slide 6

Slide 7

Slide 8

Slide 9

Slide 10

Slide Title

Slide 11

Slide 12

Slide Title

Slide 13

Slide 14

Slide 15

Slide 16

Slide 17

Slide 18

Slide 19

Slide Title

Slide 21

Slide 22

Slide 23

Slide 24

Slide 25

Slide 26

Slide 27itle