The $11 billion Metro Tunnel project is one of the largest public transport investment in Victoria’s history. The new tunnels connect the Sunbury and Cranbourne and Pakenham lines, supported by twin nine-kilometre tunnels and five new underground stations.
Behind the scenes is a vast network of emergency and maintenance accessways. Working alongside Stilcon Steel and the Southern Program Alliance (SPA), Moddex was engaged to design and supply custom pre-engineered handrail systems for the cross passages, cross tracks, and the emergency egress stairs at three underground stations.
Custom design for a complex environment
Our in-house design and engineering team partnered with Stilcon Steel to develop custom, wall-mounted HDG Tuffrail handrail systems for both the cross passage (CP) and cross track (CT) walkways.
Cross passages connect the two rail tunnels and serve as evacuation routes, pressure zones and maintenance access points. By nature, they come with irregular geometry, tight clearances and steep level changes. Cross tracks run parallel to the rail corridor, providing access for inspection and emergency response, and are subject to vibration from rolling stock, moisture from tunnel drainage and corrosive conditions.
Together, the CP and CT walkways required solutions that were safe, compliant, durable and installable in highly constrained conditions. Moddex engineered a handrail system modelled to suit the as-built survey data, delivering:
- Custom pipe bends and transitions to match complex floor profiles
- Variable elbows and connectors to follow tunnel curvature and adjust onsite
- Modular components for weld free installation, avoiding hot works
- Robust wall mount fixings suitable for tunnel environments
These components formed fully pre-engineered kits, supplied ready for installation across long distances and ensured each rail run remained continuous, smooth and compliant within the limited space.
Fire and emergency egress stairs at three stations
Moddex also supplied handrail and balustrade systems for the fire and emergency egress stairs at Flagstaff, Parliament and Melbourne Central stations.
These areas sit deep within the station infrastructure and often present significant access constraints during construction. Much of the work took place in narrow shafts and heavily scaffolded zones where space for fabrication and assembly was limited.
At Parliament Station, for example, upgrade works required new access platforms inside existing draft vent relief shafts. Under a collaborative delivery model with SPA, contractors carried out installations in exceptionally tight conditions, with some sections requiring installation from on ropes due to the steepness and confinement of the shafts.
In these environments, Moddex’s bolt-together assemblies proved particularly effective, being able to be manoeuvred into confined areas, aligned with the existing geometry and installed without hot works or large tools.
Proudly supporting one of Victoria’s biggest infrastructure projects
The Metro Tunnel opening marks a major milestone for Melbourne’s transport future, and Moddex is proud to have played a role in supporting Stilcon Steel, SPA and the wider delivery teams in bringing this project to life.