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Brunt Road Level Crossing Removal Project

Brunt Road Level Crossing Removal Project

Moddex’s Solutions Ensure On-Time Delivery and Safety Compliance for Brunt Rd LXRP

Client name: Metropolitan Roads Program Alliance
Location: Beaconsfield, Brunt Rd, Victoria
Project type: Roads & Infrastructure

Moddex played a key role in the Brunt Rd Level Crossing Removal project by supplying bikeway barriers, access handrails, and safety barriers for the newly constructed road bridge.

The level crossing was removed in April 2024, a full year ahead of schedule. It marks the 76th level crossing removed as part of the Victorian Government’s Level Crossing Removal Project, which involves removing 110 dangerous and congested level crossings across Melbourne by 2030. The new bridge has brought about many benefits including:

Significantly reduces congestion for the 8,400 vehicles that previously passed through the level crossing daily.
Allows for more frequent train services.
New paths across the bridge provide a direct link to local schools, shops, and services on either side of the rail line.
Drivers, cyclists, and pedestrians now have a safer, more reliable way to cross the Pakenham Rail Line.

The Challenge

It was a challenging project, especially as there was an urban design brief to meet. This had to consider both the built and unbuilt spaces, as well as the people who live and interact within them. It’s a collaborative process that aims to create places that are functional, aesthetically pleasing, and sustainable, ultimately improving the quality of life for residents.

The project required custom-modified balustrade and handrail systems to suit unique site conditions, while most importantly remaining compliant. Moddex were selected—our proven ability to meet stringent compliance requirements is well recognised and respected across the industry. In addition, our competitive pricing, thoughtful design, flexibility, technical knowhow, industry experience, and commitment to service, led to us being specified and ultimately awarded the project.

Moddex solution

Moddex worked closely with the design engineers, Tract, for 12 months prior to the project’s start, given the project’s complexity. This early partnership was crucial, allowing for challenges and project specific requirements to be identified and resolved before work commenced on site.

“This proactive approach ensured that contractor Fulton Hogan could meet deadlines and stay within budget by following the designer’s specifications,” said Moddex Key Account Manager, “By resolving issues ahead of time, we eliminated unnecessary back-and-forth, saved valuable time, and ensured the project was compliant from day one.”

The following Moddex systems were installed:

BikeSafe Bikeway Barrier BS45
AssistRail Disability Handrails AR45 and AR70
Conectabal Commercial Balustrade CB10
TuffRail Industrial Handrail TR20

One of the project requirements was to integrate our system with the Anti-Climb barrier that was already installed, which required customisation of our system and processes. This type of requirement can be challenging without the intelligence of our CAD systems. By utilising the client’s design files for the Anti-Climb, Moddex were able to integrate them with our own CAD system, ensuring perfect alignment and a seamless transition.

“This was by far the most complex aspect to overcome” said Kaine Jamieson, General Manager at Moddex, “however thanks to the flexibility and design capabilities within our company and systems, what may have seemed like a major issue externally was relatively straightforward for Moddex.”

Certain sections of the project required the integration of our Tuffrail and Bikesafe systems with mesh. Mesh was a critical requirement on specific areas of the bridge—both rail and road—to prevent loose objects from falling onto trafficable areas below. We also provided a mix of hot-dip galvanised (HDG) and powder-coated finishes, which were selected primarily to meet the aesthetic goals outlined in the urban design brief.