Project Details
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Date Completed
2020 to 2021
$600 million
John Holland (NWPA)
Melbourne, Victoria

Stilcon Scaffolding was engaged, by John Holland to work with them on the 2km Skyrail project. This project involved the removal of two level crossings between Moreland and Coburg stations respectively. The $600 million project was scheduled to be the largest occupation of the southern hemisphere with a program to complete over 90 days. In an unprecedented event the project was completed 30 days ahead of schedule.

Due to the expected 90 day occupation schedule, along with the complexity of the suburb itself and the elements involved in the area we were working – this project required a 24/7 approach as the disruption of the area needed to be reduced to the shortest time possible. The high living density of the area and the disturbance of the environment meant that the schedule needed to be so tight, to meet community expectations.

As a team, in preparation, we ensured an intricate understanding of the elements of the project and the two new station builds. We identified that we had to design scaffolds to work within very tight areas and enable safe access while incorporating the two new build stations with the trainline infrastructure. We planned the schedule logistically to meet John Hollands program dates, helping them keep the project timeline on track – but ensuring flexibility.

One of the innovative designs our team developed was a retractable stretcher access to enable the high roller to put the railway tracks in the u troughs of the Skyrail. Our team project managed the design, build, installation, and management of this stretcher, which John Holland want to use on future projects.

Our agility, customer service and can do approach, coupled with our young driven dynamic team was instrumental to executing the job within such a challenging environment. The actual logistics of delivery of equipment and team was achieved through the responsiveness of the entire team (design & engineering, administration, warehouse & dispatch, transport & logistics) respectfully, supporting each other and working together to ensure the extreme pace required was able to be maintained for the duration of the project.

The team identified, from previous level crossing experience, that to ensure reliability for the onsite team they needed to be self-sufficient. This could only be achieved by Stilcon Scaffolding supplying all their plant equipment and transport needs. The team ensured that all materials met the rail compliance standard necessary. The innovative ideas from the team meant onsite they could move faster and smarter – such as always having a Stilcon Scaffolding rail compliant ute onsite, removed the need to rely on other services. This in turn lead to more efficiencies on the job, which benefitted the client in maintaining the timeline.

At the end of this project John Holland recognised the cohesiveness achieved between the two teams and appreciated working with a team with such strong team culture and internal safety cultural. Stilcon Scaffolding will continue to work with John Holland across their next three level crossing projects (Glenmore, Preston & Vail).

We’re reliable, we’re respectful and we take responsibility.


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Stilcon Scaffolding now Stilcon Industrial Services

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