Workshops are the beating heart of any rail operation. This is where the real work happens—where heavy machinery gets stripped down, repaired, and put back into service. For Progress Rail, a key player in locomotive service and repair, ensuring worker safety while maintaining efficiency was non-negotiable. When their Cardiff (Newcastle) facility identified critical risks in locomotive roof access, they turned to a solution that would transform their maintenance process: an overhead mobile gantry system.
Progress Rail made the smart move of rethinking its approach to height access, following a five-step process—from scoping to boots-on-the-ground support from height access industry experts. Here’s how it was done.
Addressing a Major Safety Concern
Locomotive roof access during rebuild and maintenance projects has always been a high-risk task. Workers were exposed to vertical access ladders, inadequate edge protection, and large gaps that posed serious fall hazards. Additionally, dropped objects were a constant concern, as was the reliance on cumbersome harness systems that slowed down work.
Progress Rail needed a system that would meet and exceed regulations. The goal was clear: eliminate fall risks, remove the need for harnesses, and introduce a safer, more efficient access method.
Building Safety from the Ground Up
Instead of relying on traditional access methods, Progress Rail took a worker-first approach by engaging directly with their site crew. SafeSmart Access’ rail industry expert worked closely with the team to understand their daily challenges and identify what a real-world, user-friendly solution would look like.
The result? A robust overhead mobile gantry system, featuring:
- A guide wheel with a 125mm double flange track on the 70-degree ladder side for increased stability, this removes the risk of user error when positioning the gantry.
- Standard locking castors to secure placement and prevent unintended movement.
- Protective mesh on all sides to eliminate fall risks and prevent tools or debris from becoming hazards.
- Sliding access gates and removable internal guardrails for unrestricted, safe movement.
It didn’t just get the job done—it took a day-to-day activity from antiquity to cutting-edge innovation.
Commercial Proposal – Safety Meets Efficiency
Progress Rail didn’t just need a safer solution—they needed one that made business sense.
The 3.6-metre gantry system was engineered to maximise maintenance space while being specifically tailored for Pacific National’s 82-class locomotive fleet.
With customised design elements that optimised both safety and efficiency, Progress Rail could confidently justify the investment. The new Mobile Locomotive Roof Access Gantry outcompeted previous methodologies in every metric – time, safety, and efficiency.
- Cost efficiencies through reduced maintenance downtime.
- Increased worker productivity without sacrificing safety.
- Long-term savings by eliminating scaffold assembly, flimsy ladders and harness-related delays.
After sign-off from the client, the gantry could now enter production and then delivery.
A Seamless Implementation
With the design finalised, the manufacturing and logistics process kicked into high gear. Built in New Zealand, the gantry was shipped to Australia and installed on-site without disruptions to operations.
One of the most impressive aspects? The system’s intuitive design meant that maintenance crews could use it immediately, with minimal training required. There was no lengthy onboarding or complex operational changes—just a smarter, safer way to work.
And it was a clear winner amongst the crew. With safety and efficiency improved on site, the team are keen to get their hands-on another for their workshop.
Boots-on-the-Ground Support
Unlike a one-and-done installation, Progress Rail knew that long-term boots-on-the-ground support was critical to keeping their safety systems at peak performance.
That’s why SafeSmart Access continues to work alongside Progress Rail to:
- Conduct regular compliance checks to ensure ongoing adherence to AS1657:2018.
- Offer proactive maintenance support to prevent unexpected issues.
- Stay engaged with site crews to adapt the system to evolving operational needs.
This is the equivalent of having a pit crew that doesn’t just service the car but also fine-tunes it to squeeze out every last bit of performance. The gantry wasn’t just installed and forgotten—it gets constant expert attention to ensure it keeps performing at its best.
Blueprints for Success
Progress Rail’s successful implementation of the mobile gantry system is more than just a project win—it’s proof that designing smarter, safer maintenance solutions is what we do best. Whether it’s an off-the-shelf platform or a custom-engineered solution, SafeSmart Access has the expertise, the innovation, and the team to get it done.
Our blueprints for maintenance solutions aren’t just theoretical—they’re physical platforms that are practical drivers for real-world results, and after 15 years, we’re damn good at it. With career engineers and face-to-face industry experts, we don’t just design equipment—we change how worksites operate for the better.
So, if you’re ready to rethink height access and eliminate the pain of workshop maintenance, talk to the experts who make it happen.
Ready to take your rail safety to the next level? Connect with height access industry experts today and discover how boots-on-the-ground support can transform your operations.
