How Sydney Trains Innovatively Implemented Cantilever Platforms to Streamline Maintenance Operations
Rail networks are the circulatory system of a city, and keeping them running smoothly requires constant upkeep. However, rail maintenance processes are often fraught with inefficiencies, approval challenges, and static infrastructure struggling to meet modern demands. A scene where SafeSmart Access aims to alleviate some of these pains with practical platforms for the task at hand.
Housed at Sydney Trains’ Granville facility, are extremely high-tech track vehicles that are responsible for ‘scanning’ the entire Sydney Trains rail infrastructure network every 2 weeks, monitoring for defects, developing faults and any preventative maintenance that is needed to keep the network in top condition. Here, in Granville, the maintenance teams encountered a particularly persistent issue: two maintenance roads—one equipped with a service pit and the other without—yet no efficient means of transferring a cantilever platform between them. The consequence? Time-intensive and costly repositioning of track vehicles for routine inspections. That’s when Sydney Trains reached out to our rail access industry experts at SafeSmart.
Identifying the Maintenance Challenges
The existing cantilever platform at Granville was not designed to work over the pit road, requiring maintenance crews to reposition rollingstock vehicles frequently. The essential track vehicles based at Granville need regular inspections to be maintained in perfect working order, and without a more flexible solution, the process risked delays, increased costs, and potential service disruptions. The key task for the Cantilever Platform was accessing the highly sensitive camera equipment mounted to the front and rear of the track inspection vehicle. This equipment needs to be cleaned of any debris between each deployment of the vehicle, a sometimes more than daily task.
A review of the system made it clear: the existing platform, supplied previously by SafeSmart Access in 2018, needed a serious upgrade. The challenge was figuring out how to make it work with the service pit while keeping it safe, efficient, and easy to use.
Integrating Solutions with Existing Access Platforms
The solution needed to ensure compliance with AS1657:2018 standards and cater efficiently to maintenance tasks over the service pit. A strategic decision was made to adapt the existing cantilever platform – initially intended for the flat road without a pit – to accommodate the pit’s unique requirements.
A critical step in the solution was ensuring that the cantilever’s deployment would not require additional personnel, thus minimising labour costs and maximising safety.
The cantilever platform’s base was redesigned with a custom rail wheel chassis that could roll along tracks with ease, four wind down castors for movement between pits, and brakes across the sets of wheels. All without compromising the platform’s cantilevering capabilities or inhibiting the work area around the workshop.
What is the Cantilever Platform?
Central to the platform’s success is its form and functionality. Designed to address unique site requirements, such as maintenance accessibility for locomotives and general vehicular maintenance, the off-the-shelf cantilevered platform features a range of innovative solutions:
- A unique cantilevered extension that lets it extend over voids or obstacles.
- Lightweight aluminium construction for easy manoeuvrability
- Built-in guardrails and gates for maximum worker safety
- Rubber wheels with directional locks for precision positioning
Not just another maintenance ladder—it’s a workhorse for workshops across a multitude of industries.
Tailored to Needs
The commercial proposal for the cantilever platform included enhancements that addressed safety, durability, and performance. The platform had to endure the rigours of frequent use and provide frontline workers with secure and stable access. This involved equipping the cantilever with rubber wheels, rail wheel chassis, and locking mechanisms to maintain precision when moved across different terrains.
An itemised quote was provided to project stakeholders, detailing costs to ensure the longevity and sustainability of the platform. By focusing on the current and future state of the equipment and the surrounding infrastructural demands, Sydney Trains was assured that the investment would bolster long-term operational efficiency and safety.
Effective Setup and Implementation
The implementation phase was crucial for ensuring that the solution met all safety requirements and operational needs. The task was taken on by workshop engineers at Sydney Trains, who was able to set up the cantilever platform over the pit road seamlessly within a constrained time frame.
“I was finally able to get time to get the cantilever platform set up on the pit rail. It works an absolute treat, and was much easier than I expected.
I was also able to do it by myself, without any help from another tech.”
Remarkably, the setup was quick and carried out single-handedly, underscoring the user-friendliness and ergonomic design of the platform.
The result? Less time wasted shunting vehicles between maintenance roads, fewer operational costs, and an all-around win for efficiency. Workers could now perform inspections faster and with minimal disruption to Sydney Trains’ tight schedules.
Ensuring Ongoing Safety and Compliance
Sydney Trains further demonstrated foresight by planning for the through-life support of the cantilever platform. Regular inspections and maintenance protocols were proposed to ensure that the setup remains compliant with AS1657:2018 and other safety standards crucial in rail infrastructure.
Regular monitoring ensures that wear and tear, particularly on high-impact zones like the platform wheels, are promptly addressed. This approach guarantees the equipment’s longevity and sustains its operational integrity, aligning with Sydney Metro’s rigorous maintenance regimen.
Exemplifying Modern Rail Maintenance
This project is proof that good engineering can make all the difference. By rethinking an old solution and tailoring it to unique, real-world needs, Sydney Trains cut down on inefficiencies, improved safety, and saved money in the process.
Through this strategic initiative, Sydney Trains continues to meet its operational objectives within safety standards, ensuring reliable service delivery across the Sydney Metro area.
Practical, effective, and game-changing are the results that SafeSmart delivers to client challenges. And we are always here to pave the way for further enhancements in rail maintenance practices, just get in touch!
