---
title: TfNSW Bridge FRP Subcontract Pattern
type: concept-note
status: live
created: 2026-05-04
created_by: cowork-lfcs (Phase 7)
applies_to_job_types:
  - bridge
  - bridge-substructure
  - bridge-superstructure
  - bridge-FRP-package
related_specs:
  - "[[AS5100 (2017) Bridge Design]]"
  - "[[TfNSW B59 Bored Concrete Piles]]"
  - "[[TfNSW B80 Construction]]"
related_concepts:
  - "[[Defensible-for-variations-posture]]"
  - "[[Common-pricing-misses]]"
canonical_examples:
  - "[[2602 - Dec Projects - Munmorah Bridge]]"
---

# TfNSW Bridge FRP Subcontract Pattern

> **When to apply:** any LFCS bid for a bridge FRP (Formwork + Reinforcement + Pour) package as subcontractor under a head civil contractor (TCE / Dec Projects / Mack Civil / etc.) on a TfNSW bridge job. Read this BEFORE pricing. Wikilink in per-job CLAUDE.md Patterns section.

## TL;DR — what this pattern locks down

1. **LFCS scope = FRP-INSTALL** of bridge concrete elements (abutments, L-walls, deck, parapets, headstocks). Bearings + Super-Ts + reo + concrete + drainage + expansion joints + barriers ALL head-contractor supply by convention.
2. **Formwork = LFCS ply only — PROPS / FALSEWORK EXCLUDED.** Major falsework (heavy propping, tower forms, cofferdams) is head-contractor scope OR Formhire subby. LFCS doesn't carry props.
3. **Cranage default = EXCLUDED both ways** (Super-T launch + parapet lift). Head contractor provides crane. **Override BoQ "Include Cranage" wording with explicit exclusion** unless Pre-Pricing-Grill confirms otherwise.
4. **Day shift only by default** (working at heights + bridge access usually rules out night). Confirm in grill — if night, midnight crossing loading applies (see [[Common-pricing-misses]]).
5. **AS5100 (2017) governs design.** Loading SM1600 + HLP320 to AS5100.2 (2017). Design life 100 years. BEDC-1 earthquake. Min lateral load 500 kN.
6. **IFI → IFC drift is the #1 commercial risk.** Bridge drawings are typically issued "Issue for Information / NOT FOR CONSTRUCTION" at bid time; "Upon project award scaled CAD drawings will be produced". **Pricing posture must be defensible-for-variations** ([[Defensible-for-variations-posture]]) — submission rate matches future variation rate so scope drift bills cleanly.
7. **Programme = ~13 weeks typical** for an FRP-install-only bridge package on a 30-35m span. Sequence: pile prep (head contractor) → abutments LFCS → wingwalls/L-walls LFCS → girder launch (head contractor crane) → deck LFCS → parapets LFCS → handover.

## Default supply boundary (FRP-install-only)

LFCS supplies (typical):
- Formwork ply (deck soffit + edge forms + abutment forms + wingwall forms)
- Walkway brackets / scaffolding for deck access (small)
- Renderoc-type patch repair material if BOQ has channel-wall repair
- Bearing mortar (tapered mortar pads under bearings)
- Curing compound + Bituthene small quantities
- Small tools + ute&tools (per Rate Card V1.7 $150/day)

Head contractor / Designer supplies (typical):
- N40-N50 concrete (graded to spec — abutments typically 40, deck 50, approach 32)
- N20 / N16 reinforcement (Grade 500N, ACRS-certified)
- Bearings (laminated elastomeric or pot — design-engineer specified)
- Super-T girders (precast supplier)
- Diaphragm beam reo + concrete
- Steel thrie beam barriers OR concrete 920-high regular performance barriers (alternative noted on most TfNSW bridge drawings)
- Bridge deck drainage system
- Expansion joints (precast or Tritoflex-style)
- Backfill behind abutments ("to civil specification")
- Pile installation (TfNSW B59 — 900 dia bored, socket into rock typical)
- Saw-cutting + pavement removal
- Pavement reinstatement
- Safety barriers + traffic management + cofferdam if water-level forces it

**Sensitivity per supply item LFCS picks up** (typical $ swing on a 30m bridge):
- Concrete supply: +$15,000-$25,000 (~80-100 m³ across all elements)
- Reo supply: +$8,000-$15,000 (~25-40T at 287 kg/m³ heavy-bridge density)
- Bearings supply: +$6,000-$12,000 (8 bearings, AS p/n premium)
- Super-T supply: NEVER LFCS scope (precast)
- Cranage: HUGE — +$30,000-$60,000 if LFCS provides Super-T launch crane; +$5,000-$10,000 for parapet lift
- Cofferdam: +$25,000-$50,000+ if water level forces it (specialist subby)

## Risk tags (always carry on bid submission)

| Risk | Severity | Mitigation in submission |
|---|---|---|
| IFI drawings → IFC drift (extra detail / dimension changes) | HIGH | Defensible-for-variations posture; variation rate basis attached; allow 5-10% of bid as VO buffer in commercial review |
| Bearing supply/install split unclear at bid time | HIGH | Confirm in QS call; default to install-only unless explicit |
| Steel thrie beam vs concrete barrier alternative | MEDIUM | Concrete option = +1000mm deck/abutment width = different scope. Confirm in QS call BEFORE pricing |
| Carriageway dimension discrepancy between structural + civil drawings | MEDIUM | Common — structural says X, civil says Y. RFI required at bid time; price assumed to one value with carry-over note |
| Renderoc patch repair quantity TBC ('1 Item' in BOQ, not dimensioned) | LOW | RFI for cut length/area; price as Item with assumption note |
| Saltwater / coastal exposure (cover spec, durability) | MEDIUM | If site within 100m of saltwater: cover spec changes; AAR-test extra rigour |
| Working at heights (3m+, 6m+) | MEDIUM | Productivity de-rate ~10-20% per Rate Card V1.7 day rates already include allowance |
| 0.05% AEP flood not impacting | LOW | Per typical TfNSW design note — confirm site-specific |
| Pile installation delay (head-contractor scope) | HIGH | Pre-condition to LFCS mob; variation if pile-out delays push LFCS programme |
| Existing services proximity (live electrical, water, telecoms) | HIGH | DBYD pack required pre-mob; service-strike repair excluded unless direct LFCS strike |

## Key references (always read)

- **AS5100 (2017)** — Australian Standard Bridge design code. Parts 1-7 cover design loads, structural, foundations, bearings, joints, etc.
- **TfNSW B59** — Bored concrete piles spec (typical pile foundation)
- **TfNSW B80** — Bridge construction spec (general construction quality)
- **TfNSW B82** — Bridge cast-in-situ concrete spec
- **R0271 / R0272** — Standard bridge details (parapets, expansion joints, drainage)
- **Northrop Consulting Engineers** — common TfNSW bridge designer (Newcastle + Sydney offices). Their drawings stamp "Issue for Information / NOT FOR CONSTRUCTION" → IFC issued post-award.

## Pricing pattern — refer to pricing-checklist.md

1. **Phase 0 — Pre-Pricing-Grill MANDATORY** before any rate set. Bridge-specific Q-A items: bearing supply/install split, parapet supply (precast vs cast-in-situ), thrie beam vs concrete barrier alt, deck pour single vs multi-pour, cranage explicit confirmation, cofferdam likelihood, programme constraints (day vs night vs weekend).
2. **Productivity calibration for bridge work** (typical):
   - Formwork: 1.7 hrs/m² heavy abutment, 1.5 hrs/m² wingwall, 2.0 hrs/m² deck (working at heights)
   - Reo fixing: 22-25 hrs/T (heavy ~287 kg/m³ density typical for bridges)
   - Concrete pour: 1.0-1.2 hrs/m³
   - Strip: 0.4-0.5 hrs/m²
3. **Phase 5 mandatory output structure** (per pricing-checklist Phase 5): 6-sheet Tender + 5-sheet Buildup + Calc Basis column.
4. **Defensible-for-variations posture** ([[Defensible-for-variations-posture]]) — bridge IFI → IFC drift makes this NON-NEGOTIABLE on TfNSW bridge work.
5. **15% redundancy** on subtotal.

## Canonical example — 2602 Munmorah Bridge

See [[2602 - Dec Projects - Munmorah Bridge/CLAUDE]] for the full per-job context.

Pricing story: Phase 0 grill applied upfront (signed off in `02b/Pre-Pricing-Grill-2026-05-04.md`), pricing v1 cut at $407,870 ex GST first-time-right (vs 2626's 5-revision iteration). All 9 lessons from 2626 Rounds 1-3 hit on first attempt. Submission-ready pending Tuesday QS call answers.

If you're pricing a similar bridge FRP subcontract, **start from this concept note + the 2602 reference + Pre-Pricing-Grill template, not from a blank slate.** The lessons are baked in.

## Quick query — "all bridge-shaped jobs in Airtable"

Filter `Jobs` table by Notes contains "bridge" OR Name contains "Bridge" — until we add a `Job Type` field (Phase 8 candidate).