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FRP in Rail Case Studies: Safe Access Platforms and Station Upgrades
This Tech Talk Tuesday session examines how FRP is being used in real-world rail projects across the network, rather than just in theory.
Edward walks through several applications where traditional metallic solutions were complex or high-risk because of:
- Proximity to overhead wiring and stray current concerns
- Restricted access that limited the use of cranes and heavy lifting equipment
- The need for lightweight, modular systems to speed up installation
- Durability and maintenance issues with conventional materials
Using those constraints as the starting point, FRP platforms, walkways, handrails, and permanent formwork were employed to deliver safer, faster, and more durable outcomes.
Key benefits of FRP in these rail projects
- Lightweight and stick build friendly
FRP components can be carried in by hand and assembled like a large Meccano set, ideal where overhead wiring or live tracks prevent crane access. - Non-conductive in electrified environments
FRP removes many earthing and bonding requirements and reduces the risk of stray current and touch potential in substations, stabling yards, and near overheads. - Durable and low maintenance
FRP does not rust and does not rely on coatings for protection. With the right surface finish, it avoids the roughening and glass splinter issues seen with unsuitable composite products. - Prefabricated yet adjustable on-site
Pre-cut, pre-drilled, and pre-assembled modules reduce installation time while allowing on-site adjustments if required. - Anti-slip performance for public and staff access
FRP grating and solid decking products are available with high-performance anti-slip surfaces suitable for rail corridors and station platforms. - Smart access to buried services
Interlocking FRP boards that can be removed individually allow platform and walkway surfaces to be lifted without dismantling large areas when services beneath need maintenance. - Compatible with hybrid structures
FRP can be combined with steel or concrete where it makes sense structurally, while still delivering electrical and durability benefits in critical zones.
Applications showcased in this session
Elevated Safe Access Platforms (ESAP) in stabling yards
Challenge
- Trains are stabled for cleaning and maintenance.
- Staff previously climbed onboard using train-mounted ladders while carrying tools, cleaning gear and waste.
- Overhead wiring and live refuge tracks limited crane use and made metallic structures difficult due to earthing and bonding requirements.
FRP solution
- Full FRP elevated safe access platforms installed along the stabling roads.
- Platforms are designed and supplied as pre-cut, pre-drilled kits with pre-assembled handrail panels.
- All components were brought in by hand along concrete paths because overheads could not be isolated.
Outcome
- Around thirty ESAP structures were installed in approximately thirteen days.
- Safer boarding for cleaners and maintenance staff with proper platforms and handrails instead of ladders.
- Non-conductive system reduced earthing and bonding complexity and improved safety around overhead wiring.
Melbourne rail corridor access stairs and a Five-foot walkway
Key elements
- Small FRP stair units provide step-overs across concrete sections in the rail corridor.
- A central FRP walkway in the five-foot using an interlocking solid board system.
- Use of micro-mesh grating for open areas where limited drainage and dropped-object control are required.
Why FRP worked here
- Preassembled stair units
Stairs were fully assembled at Treadwell’s facility, then lifted into position by a high-rail truck and secured on site, saving installation time. - Interlocking solid walkway
The central walkway uses a tongue-and-groove type system that allows a single plank to be removed without disturbing adjacent boards. This is important for future access to services beneath. - Installation under tight time frames
Lightweight FRP enabled faster handling and expedited transport, helping the project meet tight reopening deadlines.
Glenfield Junction platform coping formwork
Challenge
- Raising the platform edge for new rolling stock introduced stray-current issues when metallic permanent formwork or coping angles were used.
- There were concerns that people might experience a tingle from nearby items, such as light poles, due to the current paths through the reinforcing steel and metal edging.
FRP solution
- A custom FRP angle was developed as permanent formwork for the platform coping edge.
- The angle acts as the front face of the new platform extension and remains in place after screeding.
Outcome
- Removing the non-conductive FRP eliminated the electrical path that had caused stray-current concerns.
- Components were lightweight enough to be carried into positions with limited machinery access.
- The FRP angle provided a durable, uniform edge that was corrosion-resistant for long-term service.
Rosanna station FRP platform extension
Challenge
Platform extension required over an area with extensive services beneath, including conduits and other utilities.
Conventional solutions, such as cast-in-place concrete or asphalt infill, would make future access to those services difficult and invasive.
FRP solution
Use of Treadwell’s FRP deck system as the platform surface.
Interlocking boards are designed so that a central panel can be removed without disturbing adjacent planks.
Anti-slip surface suitable for public traffic and exposure to weather.
Outcome
A platform extension that can be selectively opened for maintenance without major demolition.
Durable, anti-slip surface suitable for long-term public use.
Maintenance teams retain practical access to buried services, reducing disruption and costs over the asset’s life cycle.
Key Moments
- 00:29 👋 Welcome back to Tech Talk Tuesday sessions every two weeks, focusing on FRP in various applications.
- 01:11 🚄 Discussion centers on the rail industry, emphasizing the critical need for infrastructure upgrades and maintenance.
- 02:07 🔧 Four FRP projects in the rail sector will be explored, detailing benefits and applications.
- 02:33 🏗️ An elevated safe access platform (ESTAP) for train maintenance was developed to replace unsafe ladder access.
- 04:14 🛠️ FRP's lightweight nature allowed manual installation of platforms without heavy machinery, completing the job in just 13 days.
- 05:36 🌧️ The Raillex product was chosen for durability and safety, addressing previous issues with unsuitable materials.
- 06:18 ❓ Q&A is open throughout the session for audience inquiries on FRP projects and compliance.
- 07:16 🔍 FRP products are tested for compliance and suitability for various engineering requirements, including fire and seismic performance.
- 09:02 💡 An innovative central walkway design allows easy removal of panels for maintenance without disturbing adjacent components.
- 10:27 ⚡ FRP was used as permanent non-conductive formwork to mitigate electrical issues at Glenfield Junction.
- 12:12 📏 The tread stage at Rosanna station showcases FRP's adaptability for platform extensions over existing underground services.
- 14:05 📅 Future webinars will continue exploring FRP applications, with information shared via social media and email updates.
Why Treadwell for FRP in rail
- Deep experience in rail environments
Treadwell has supplied FRP solutions for stabling yards, stations, substations, tunnels and access structures across multiple networks. - Rail-focused products and details
Systems such as ESAPs, treaded FRP deck boards, rail-suited handrails and fencing are designed with electrified rail requirements and possession windows in mind. - Engineering support and prefabrication
Structures are designed, detailed, pre-cut, and often pre-assembled so that installation on site is as quick and straightforward as possible. - Proven durability and safety performance
Products are selected and finished specifically for Australian conditions and rail loadings, with anti-slip and long-term performance at the core. - Flexible project support
Treadwell can assist with concept development, design support, site advice, and installer training to ensure FRP is used correctly and delivers the intended benefits.
