SmartStairs has debuted on Australia’s National Land Transportation Network. The temporary stair tower system has featured along the 15 km addition to the M1 Pacific Motorway Extension to Raymond Terrace to secure a logistic artery between Sydney and Brisbane.
Once complete, the M1 extension will save motorists 7 to 9 minutes in travel time during peak periods and bypass five sets of traffic lights.
This is SafeSmart Access’ story of how innovation met infrastructure and how they rose to meet one of the project’s most daunting obstacles—temporary towers in high-risk wind zones.
Understanding Infrastructure Wind & Scheduling Challenges
SafeSmart assigned a contracts administrator and project manager during the consultation period for John Holland Gamuda Australia Joint Venture (JHGAJV) to deeply understand their needs on-site.
The requirement for JHGAJV was to provide uninterrupted access to formwork structures, road decks, and bridge beams during construction without anchoring to the formwork or road deck, all while withstanding high winds in Wind Region A (up to 147 km/h).
The project’s accelerated pace further complicated this, requiring quick deployment and relocation of access systems to other bridge construction zones. The team needed an innovative, freestanding solution that ensured safety and efficiency without compromise.
Collaboration, Iteration, Innovation, Solution
SafeSmart’s contract administrator and project manager collaborated with the JHGAJV project delivery team to approach the challenges. They explored all options, including Proscaf Stair Towers, Aluminium SmartStairs, and AdjustaStairs.
Traditional scaffolding was quickly ruled out due to the tying requirements and the labour involved in stair movements. Minimising labour was a key consideration; the more labour required, the more risk to the safety and program for the client.
With these factors in mind, the combination of AdjustaStairs (for lower-level accesses) and Steel Stretcher Access, SmartStairs, was eventually selected as the most efficient, appropriate solution. Key features of the SmartStairs provided additional benefits:
- Quick-release pin connection; this allows the SmartStairs to be joined or disconnected in modules, to create different height stairs in under 15 minutes.
- Stretcher width design, allowing the site’s rescue plan to be created using SmartStairs.
- Accommodation for AdjustaStairs or AdaptaSpan joining systems; to create exit points to various levels of the structure.
Working with the client engineers and third-party engineers, the SafeSmart Engineering team evaluated and certified the SmartStairs for a free-standing, untied height of up to 18m while accommodating the required 147 km/h wind loads.
Temporary work designs were completed to carefully plan the project’s use cases. With the engineering challenges addressed, the focus shifted to justifying the solution from a business perspective.
Dotting the I-Beams and Crossing the T-Beams with a Commercial Proposal
SafeSmart assisted the client in building a business case that clearly outlined how the proposed project solutions met all the evaluative criteria, and demonstrated clear tenets of innovative that result in tangible efficiency to program and cost.
The ‘fixed price’ submission by SafeSmart made it easy for the client to evaluate the actual program cost compared to variable scaffold labour costs.
SafeSmart helped JHGAJV build a robust business case. By clearly outlining how the proposed systems met all evaluative criteria and showcasing tangible efficiencies in both program and cost, they demonstrated the solution and the project’s innovative edge.
A ‘fixed price’ submission simplified the client’s ability to evaluate the actual program cost, especially when compared to the variable and often unpredictable costs associated with scaffold labour. This financial clarity was a game-changer, making it easier for decision-makers to see the value proposition.
Adopted as a solution, it was time to bring the solution to life on the ground.
Delivering Results for Bridge Construction
With the pace of break-neck construction underway, SafeSmart’s delivery plan fulfilled the scheduling requirements through a series of service enhancements.
By organising a team of qualified riggers to pre-assemble the Stair Modules and coordinating weekly pickups with the client, a constant flow of modules were being delivered to site, ready for use.
During this time, training was conducted with JHGAJV, ensuring a thorough understanding of the product and fulfilling the temporary works training requirement from the award.
For quality assurance, visits by client during manufacturing and assembly were conducted and all modules were inspected by SafeSmart engineers to ensure fit for use on site.
These service enhancements complement the philosophy behind SafeSmart – rapid response, lasting results.
Supporting SmartStairs Now and Future
The SmartStairs system supplied to M12RT is a stocked, off-the-shelf product, capable of both above-ground and below-ground applications. Not a custom one-off solution, but a versatile stair system suitable for ongoing projects between the joint venture parties across Australia.
What this means for clients like John Holland and Gamuda Australia is ongoing support and maximum utility from their investment by reusing the temporary stair tower system for multiple uses. Robust, enduring, and safe, it’s guaranteed the stair towers will be seen across many sites in the future after their tenure on M12RT.
SmartStairs Snapshot
The SmartStairs system features a flat-packed design for easy assembly and part replacement, with a robust painted or galvanised finish. Its unique sliding pin connection ensures simple module attachment, while 25x25mm safety mesh and removable exit panels enhance on-site safety. Certified crane lifting points and internal harness attachment points add security. Compliant with AS/NZS 1657:2018 & 1576:2018, it’s supported by regular inspections, audits, and maintenance for long-term reliability.
Temporary Stair Towers Solutions for Infrastructure Construction
Throughout the project, SafeSmart’s contract administration and project management personnel were consistently available to JHGAJV. This hands-on support ensured that any issues were promptly addressed and the project stayed on schedule. The client was continually impressed with the clear communication, ease of product use, and technical guidance provided by SafeSmart.
SmartStairs, as the go-to temporary stair tower solution, addresses on-site challenges that traditional scaffolding cannot. Its freestanding, adaptable, and easily movable design fills a significant gap in the market, enhancing safety, reducing labour costs, and improving efficiency.
The success of SmartStairs on the M1 Pacific Motorway Extension demonstrates its effectiveness as a reliable alternative to scaffolding. It not only solved immediate access challenges but also provided JHGAJV with a reusable asset for future projects.
Without the right tools and expertise, bridging your challenge to a solution can be difficult. Let SafeSmart provide innovative, reliable access solutions to ensure safety, efficiency, and success on your next project.
