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Pacific Highway Upgrade - Sancrox Interchange

Completed Projects

In February 2014, Roads and Maritime Services (RMS) awarded Ferrovial Agroman Australia the contract to build the Sancrox Interchange, near Port Macquarie on the Mid North Coast of New South Wales. This was the first stage of the Pacific Highway Upgrade Program between the Oxley Highway and Kempsey and Ferrovial's second awarded construction project in Australia.


Project Term

2014 - 2015


Roads and Maritime Services (RMS)


Sancrox - Port Macquarie, NSW

The Pacific Highway Upgrade Program is a joint commitment by the New South Wales and Federal Governments to provide continuous dual carriageway on the Pacific Highway between the Hunter and New South Wales/Queensland border. The upgrade of the existing highway to dual carriageway will improve transport safety and efficiency, reduce crashes, assist with economic development, improve freight costs and travel times, allow for the separation of local and through traffic and provide a safer and more efficient section of the transport network of NSW.

The Sancrox Interchange project involved the construction of a bridge over the Pacific Highway approximately 600m south of the existing Sancrox Road Intersection and construction of associated local service road network.

Generally, the local roads include two 3.5m wide travel lanes and 2.0m wide shoulders. The pavement construction is varied between thin asphalt over heavy bound base over selected material zone or a dense graded base pavement with a spray seal over selected material zone. Three large Roundabouts [designed to facilitate traffic in the future industrial developments] are constructed from steel fibre reinforced concrete base over lean mix concrete subbase.

The bridge over Pacific Highway consists of a two span simply supported PSC Super T structure. Spans 1 and 2 are 27m and 32.1m respectively with an overall length of deck of 61.05m. The bridge has a constant carriageway width of 9.50m, comprising two 3.5m traffic lanes with a shoulder either side of 2m and 0.50m width respectively. A shared use path 2.5m wide is provided along the Southern edge of the deck with a constant 2.5% crossfall towards the external barrier.

On the 30th November 2015, the Sancrox Interchange, Ferrovial's second project in Australia and first federally funded, was opened to traffic.

Port Macquarie MP Leslie Williams said it was fantastic to see the Sancrox interchange open to traffic, adding "This State and Commonwealth jointly funded project will significantly improve traffic safety by having a separated traffic arrangement to reduce the risk of an accident and importantly will facilitate the expansion of the Sancrox industrial area"


Close to 900 personnel working more than 200,000 man hours were involved in the successful delivery of the Sancrox Interchange without any Lost Time Injury (LTI).

Early on in the project WorkCover NSW [now SafeWork NSW] and Ferrovial Agroman formally committed to ensuring the safety of workers during the construction of the Sancrox Interchange with the signing of an action plan. The Action Plan committed WorkCover and Ferrovial to developing practical and effective solutions to work health and safety, return to work and injury management throughout the duration of the project. This public commitment strongly contributed to the safety culture and ultimate success of the project.


This Project is located in an environmentally sensitive area, and was closely monitored by both State and Federal Government Environmental Agencies, as well as RMS Environment's Pacific Highway branch. The Ferrovial project team developed a comprehensive Construction Environmental Management Plan (CEMP), in order to minimize the project environmental impact and protect the local flora and fauna.

Our Environment Protection Licence (EPL No. 20419) along with approved variations, is accessible on the EPA web-site.

As required by our EPL, we have prepared a Pollution Incident Response Management Plan to ensure we are organised to act effectively if an incident occurs.


Community engagement was a key focus of the project. As a result, the project team carried out numerous initiatives to involve the community including the use of local suppliers and subcontractors, contribution to the Port Macquarie and Hastings Council to improve adjacent roads, donation of furniture to the fire brigade volunteers, cooperation with the Koala Hospital and the provision of soil and mulch for environmental purposes to the neighbouring business.


The Heavily Bound Base (HBB) incorporated into the project pavement was the result of a revised RMS specification aimed to increase the workability time of the material. FAA collaborated closely with RMS to develop this new product and carried out a thorough testing campaign to ensure it provides the expected results. This new product will ease the construction process while increasing the durability and quality standard of RMS roads.

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