One of the most anticipated elements of the Coffs Harbour bypass project – the construction of three tunnels – is now in full swing.

Those who travel the Pacific Highway regularly to Sydney or destinations south of Coffs are eagerly awaiting the day when you will miss the 12 sets of traffic lights saving more than 12 minutes per trip. The Coffs Harbour bypass is expected to be open to the public in late 2026.

Transport for NSW Regional Director North, Anna Zycki, said that following the successful completion of work to prepare for the start of tunnelling, major tunnel construction work is underway.

“This is an exciting milestone for the project and the people of Coffs Harbour,” Ms Zycki said.

“We know from the earliest discussions with the community how important tunnels are for Coffs Harbour residents, so it is very pleasing to see major work start on this aspect of the project.”

Most other road tunnels under construction across the state are being built with the use of tunnel boring machines, but because of the hard rock in the hills along the bypass alignment, these tunnels will be created through controlled blasting.

Ms Zycki said tunnel construction has started at Gatelys Road, where significant work had been done to get the site ready.

“There has been a lot of anticipation about work starting on the tunnels and now we can really get moving,” Ms Zycki said.

Before controlled blasting of the tunnels started, the site was set up to include compound offices, water treatment plants, material laydown areas and parking for plant and workforce vehicles.

Then the top exterior of the tunnel portals was stabilised with bolts and shotcrete, and the entrance to the tunnel portals was excavated using controlled blasting, bulldozers and excavators.  

The three tunnels will each contain a northbound and southbound ‘tube’, making six ‘tubes’ in total, which will be built in stages.

The longest, and where work started first, is the 410-metre Gatelys Road Tunnel. The Shephards Lane Tunnel will be about 320 metres long and the Roberts Hill Tunnel about 160 metres.

Quick facts:

Earthworks: 1.3 million cubic metres moved to date

Plant: about 600 pieces of plant mobilised

Bridges: Eight of 17 bridges under construction

Bridge piles: 108 of 272 bridge piles in place

Concrete: 6019 cubic metres used to date

For more information, visit https://www.pacifichighway.nsw.gov.au/coffsharbourbypass

Pic captions: controlled blasting at Gatelys Road Tunnel01+ 01bCleaning drilled holes and preparing explosives:Coffs Harbour bypassworkersinspect the tunnel’s drilled holes depth, angle,andspace, ahead ofthecontrolled blast.02 .03 Controlled blast_explosion detonated_captured from stationary gopro:once thesafetyprocedure is implemented including the exclusion zone and blast sentriessecure publicaccesses, theexplosion is detonated.CHB 2402-128-Media/CHB 2402-129-Media:TunnellingSolutionsSuperintendentTonyBurrowsoverseespreparatory works andcontrolled blastingat the site ofthebypass’longesttunnel, Gatelys Road Tunnel(410 metres), in Coffs Harbour.CHB 2402-028-Media:Coffs Harbour bypass team has recently started controlled blasting atGatelys Road Tunnel, an exciting milestone for the major projectfunded by the Australian andNSW Governements