ACCIONA has introduced a new generation of 3D‑printed traffic control and security huts on the NSW Government’s Western Harbour Tunnel project.

The trial marks a first for ACCIONA and reflects a strong step forward in sustainable and innovative infrastructure delivery.

The huts are made from patterned, contoured concrete that is fully recyclable. Unlike traditional huts, the concrete can be deconstructed and mixed with other materials to form new structures, directly supporting circular construction principles and reducing waste.

Each hut weighs about 2.4 tonnes and sits on a plinth so the unit can be relocated as site needs change. The production process is fast, with each hut taking about nine days to complete. This shortens the overall build period by an estimated 40 to 50 percent when compared with conventional construction.

The huts come fully equipped with lighting and power and cost 40 to 50 percent less than standard traffic control and security huts. This delivers operational value along with environmental gains.

Security Lead Duncan Kerr, who led the initiative, said the team saw clear advantages.

“This was a great opportunity to trial something completely different," Duncan said.

"The speed of delivery, cost savings and sustainability benefits really stood out, and the fact that the huts are fully recyclable aligns strongly with our project and business values.” he said.

Two huts are now in use at the Berrys Bay and Cammeray sites, with early feedback very positive.

Senior leadership has also welcomed the initiative, recognising that this type of structure is new to ACCIONA and unusual in the broader infrastructure sector.

The supplier does not typically produce traffic huts, which makes the collaboration particularly innovative.

The units are manufactured at a factory in Cronulla, where the team viewed the printing process firsthand as the huts were formed using Contoured 3D’s technology.

There is strong potential for this approach to be adapted for other uses across the project, supporting future opportunities for smarter, more sustainable construction.