For railway corridor construction staircase access, SafeSmart’s modular AdjustaStairs and AdaptaSpan components provided a safe, compliant, and cost-effective way to move hundreds of personnel across rail trenches and through active work areas on the Level Crossing Removal Project. In a high-risk rail corridor, where construction activities demand careful planning, sequencing, and strict safety control, the project is reshaping how commuters travel across metropolitan Melbourne through crossing removals and major upgrades such as new train stations, track duplication, and stabling yards accessible to all passengers on the rail network.
A part of this crossing removals project is the Southern Program Alliance (SPA), comprising of Lendlease, Acciona/Coleman Rail, Metro Trains Melbourne, and the Level Crossing Removal Project. For construction and transport industry professionals responsible for site access, temporary works, and safety compliance, their work at Edithvale, Chelsea, and Bonbeach shows how modular stair and walkway systems can be designed to suit rail corridor conditions without the cost and delay of full scaffolding.
At these locations, excavating a rail trench to pass under the roads was needed to remove where the road crossed the railway line. However, in an active rail corridor, stair construction also had to work around restricted access, tight scheduling windows, and ongoing rail operations, while still allowing workers to frequently cross from one side of the trench to the other and access into the channel.
Elevation, voids, and uneven terrain were all factors to consider, and construction activities also had to minimise noise and vibration around the live network. Additionally, a few conditions needed to be met for safe access around these obstacles. Access needed to be:
- – Stretcher compliant, which requires increased handrail heights and wider access stairs & walkways
- – Load rated to 2.5kPa.
- – A temporary installation.
Solutions to Rail Corridor Trench Access: AdjustaStairs & AdaptaSpan
Traditionally, this type of access would be solved with scaffold structures; however costs incurred through labour, components, and downtime for installation exceeded the budget and time constraints for the client.
After an initial consultation with SafeSmart Access, SPA enquired about the possibility of a custom solution instead. Through understanding their site conditions and budget estimates, the SafeSmart team determined that a combined solution of custom walkways, AdjustaStairs, and AdpataSpan would be a more viable option than scaffolding. A prefabricated stair solution also reduced time spent on site in the active rail corridor.
Faster to install, compliant to site conditions, and cheaper than scaffolding installations, the combined solution proved safer and more cost-effective for site access.
Workers could now easily access the rail trench via one staircase consisting of two AdjustaStairs and two landings, with AdaptaSpan bridging the two sides of the trench together on top. Moreover, the setup was entirely compliant for AS1657 and AS1576, and the staircase design had to comply with relevant railway engineering standards and building codes to ensure the needs of the site were met, including stretcher complaint, 2.5 kPa load rating, and moveable.
The result was a fully engineered system, built to suit the harsh rail environment and higher dynamic live loads from nearby trains, which SPA easily craned into position, connected together simply, and moved regularly as required to manage operational hazards in the active rail environment. Additionally, the modular design meant that components could be independently used or linked together to cross the trench and descend into the trench off the same walkway.
Above all else, SafeSmart delivered on time with every safety concern addressed thoroughly, taking a clear role in delivering a significant budget saving using the non-scaffold methodology. In addition, SPA was impressed with the structure’s strength and how easily it could be moved over against stripping and rebuilding scaffold every time an access requirement was moved.
Site access is a critical component of any construction project. When site traffic needs to be diverted for safety reasons, it’s essential that a safe and compliant solution is implemented quickly and easily. SafeSmart Access has provided railway corridor construction staircase solutions for many major rail projects across Australia, helping workers safely navigate the worksite while meeting all compliance requirements. And it’s as simple as contacting our team of experts who are ready to help you find the perfect solution for your next project.
Custom Design Solutions For Railway Corridor Construction Staircases
Every site presents its unique challenges, so it’s essential that the access solution you eventually select can solve your current access issues and adapt to any future changes in site requirements. The solution for Southern Program Alliance is just one example of how our range of standard products is integrated into custom solutions.
After clients contact us with their requirements, our team will work with you to develop a plan that best fits your needs, including accessibility requirements for public-facing rail projects. Our approach is to:
- Assess the budget, time, and site requirements, including early inspection of drainage, slip risks, and other corridor constraints, with details reviewed upfront because drainage management must avoid water pooling on stairs and prevent destabilizing nearby infrastructure.
- Determine suitable solutions and recommend off-the-shelf products.
- If needed, present modifications to off-the-shelf products or couple them with custom solutions.
- Move into an entirely custom manufactured product process to overcome specific issues.
Custom rail stair solutions should include safety barriers and access controls where needed to improve safety and protect the public, as these measures also reduce the risk of unauthorized entry into rail corridors.
SafeSmart Access has an established and growing range of standard products that can be used for creating modified and custom solutions. AdjustaStairs, AdaptaSpan, and AdaptaPanels are just a few of the products we have made available for use as modular components in our range of off-the-shelf solutions. In rail applications, compliant custom stair design also needs consistent risers and high-visibility, slip-resistant nosing strips to help prevent commuter trips.
Get in touch with us today to learn more about how we can help you create a solution that best meets your needs and budget.
