The NSW Roads and Traffic Authority appointed Thiess to design, construct and maintain the $100 million Karuah Bypass Project, which forms part of the 10-year upgrade of the Pacific Highway in NSW.

This involved Thiess constructing 10km of median divided dual carriageway freeway, with two major bridge crossings over the Karuah River and sensitive environments. A key feature of the bypass is an 800m long bridge that was constructed as one single structure before being severed to form two bridges - 600m and 200m long - separated by an island. These bridges are now the longest incrementally launched bridges in Australia. Environmental management was a key focus underpinning all phases of design and construction throughout this project. Provisions were made to ensure local and regional wildlife corridors were maintained and fauna movements were separated from traffic flows to reduce impact on local species.

Now completed, the bypass offers more than 30 opportunities for fauna to safely cross under or over the highway, including five glider crossings, which were a first at the time for a major Australian roadway project.