Project Overview
Moddex was engaged by long term client KiwiRail to deliver a service pit safety upgrade at the Westfield Locomotive Depot. The scope involved the design and installation of access and fall protection systems along the full length of the service pits without restricting servicing activities. This included pre-engineered platforms, stairs, handrails, guardrails and gates.
All works were coordinated digitally. The site was 3D laser scanned prior to design, and Moddex’s in house CAD team worked directly within KiwiRail’s Tekla model to ensure accurate integration and seamless drafting.
The Challenge
Upgrading safety infrastructure within an existing locomotive depot required careful integration with the current pit structure and operational workflows.
Key requirements included allowing sufficient room within the service pits for safe servicing operations, allowing removable handrail sections, navigating a bay window, and providing flexibility for future height adjustments – all without hot works.
The Solution
Moddex delivered the two continuous 45m raised service platforms and multiple stairs using Ezibilt™ pre-engineered platform and stair systems and Tuffrail® industrial handrail.
To maintain essential working space in the pits below, our engineers developed a custom double platform configuration. The primary Ezibilt™ chassis and legs were set back from the pit edge, while a secondary platform layer extended outward to maximise usable deck width.
The system was future proofed, with built in leg redundancy to allow the platform height to be adjusted simply by removing fixings, without requiring full replacement. Custom welded sockets were also prefabricated in to allow removable handrails.
In total, the project incorporated:
- Ezibilt™ modular platforms and stairs
- Permanent and removable Tuffrail® industrial handrails
- 70 self-closing butterfly gates
- Handrails configured to navigate structural constraints including a bay window
- Stair access at both ends of the platform and into the pits
- Charcoal FRP grating
The modular installation eliminated the need for welding or hot works, reducing risk and disruption.
