The Glenroy Station project involved the removal of the level crossing and lowering the rail line underground. The client, NWPA, has managed this project over a two-year period which also includes a new Glenroy Station. It was a 14-metre-deep cut (with a distance of 1.2km underground) which Stilcon Scaffolding provided drop access scaffold into the cut and bridge structure access scaffolds across the cut.

Stilcon Scaffolding ensured the team was able to meet the clients tight program turnaround – on some occasions a 24-hour turnaround – ensuring the highest safety levels were maintained (with the design and engineering) for all requirements and the potential uses of the scaffold.

The team was also prepared for the co-ordinated project to manage the logistics of the pedestrian traffic during removal of these extensive pedestrian bridges at the end of the project.

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

Glenroy Station Pedestrian Bridge -4
Play Video about Glenroy Station Pedestrian Bridge -4

The level crossing at Glenroy Road, Glenroy has been removed by lowering the rail line under the road. As well as removing the level crossing, the project has also built a brand-new Glenroy Station.

This project required the supply of a Layher scaffold pedestrian bridge spanning 18 metres from one side of the platform to the other. The Stilcon Scaffolding entire team worked together to create an innovation solution to developing this bridge as this had not been done before on any level crossing project to date, in the southern hemishpere. The DDA & BCC compliant Layher scaffold pedestrian bridge had two stretch stairs adjoined either side of the 18 metre span.

Stilcon Scaffolding also supplied a 33 metre extension to the platform, which the client required to be identical to the existing platform – was DDA & BCC compliant. Stilcon Scaffolding built this from Layher scaffold with the inclusion of unique application of paint, anti-slip substance and Tac Tiles – as required on all train platforms. Public access load-capacities of 5kPa were specified for all structures, with Stilcon designing, engineering, and self-performing all tasks end-to-end.

The delivery of this bridge required a crane, and was very technical and logistically very tight, as it required the Stilcon Scaffolding team to land the bridge across a live railway line with very tight timeframe and wind factor elements to consider. The Stilcon Scaffolding team managed the delivery of this bridge from the Stilcon Scaffolding warehouse to the Glenroy station site which required extensive traffic management.

Stilcon Scaffolding managed all safety elements of landing the bridge from start to finish working together across operations, sales, engineering, and design to deliver this outcome. The team delivered in full on time (DIFOT).

For the removal of the bridge, NWPA had a tight timeframe – which was so tight the client’s preference was to demolition the bridge as they believed this would be more efficient for their occupation. Stilcon Scaffolding felt this option was going to be more expensive than removal and assured NWPA that they could fulfil the requirements and meet the extremely tight deadline timeframes. As Stilcon Scaffolding had worked on other level crossing with NWPA they had built a strong working relationship.

This tight time frame created a very unique situation for Stilcon Scaffolding. The team had a 24-hour period of occupation from 12 am (the day after Anzac Day) to dismantle 18 meter bridge span and the stretcher stairs. They required the crane to have a different location to installation as there was now 14 metre cut between the layher bridge scaffolding and the original position of the crane. This took a significant amount of planning between the crane team and the operations team to co-ordinate such a dynamic lift of the bridge, ensuring they gave the scaffold team enough time to strip the stretcher access on both the east and west sides. Stilcon Scaffolding successfully managed the dismantle of the platform extension, the removal of the bridge and stretcher access, and clean up within the 24-hour period.

Stilcon Scaffolding supplied the plant and equipment of a 200-tonne crane to be onsite. All scissor lifts and boom lifts with a lifting study along with generators were owned and supplied by Stilcon Scaffolding for this part of the project.

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


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.

Hallam Station 2 1

The Hallam Road project determined that the best way to remove the level crossing was to build a rail bridge over Hallam Road. Stilcon Scaffolding were engaged to supply structure access onto and into the u trough as well as edge protection. Stilcon Scaffolding design and engineering team were to supply design which ensured all safety elements and logistics required for the duration of the project were meet. The team needed to fulfil all egress and aggress for all workers on a 14-metre high skyrail with one station.

The scaffold design needed to support the u-troughs to span the double carriageway road (Hallam Road) during the occupation which was critical. The safety elements where critical as the train station was still fully functioning while work was taking place and had to ensure pedestrian safety when embarking and disembarking trains. This design needed to ensure that pedestrians could walk under the scaffold while works carried on above the pedestrian area. There were significant safety elements to take into consideration for the install due to the elements of the project – trains, cars, pedestrians and the onsite workers. Our design and operations team working together smoothly was critical to ensure this was executed successfully.

Stilcon Scaffolding designed and engineered the four main lift shafts for the Hallam Station project which were built off site and project managed off site at Stilcon Scaffolding facility. We fabricated and painted the steel while building scaffolding internally and a stretcher access externally once the lift shafts were established on the concrete slab.

This produced an acceleration for the SEPA team (Hallam Station) to be able to send trades do the glass works, the façade works, and the internal mechanisms of the lift shaft – off site. Each lift shaft once fully completed weighed a total of 30 tonne. Stilcon Scaffolding team organised for the cranes and the transport and the traffic management to be able to lift them onto trucks to send to Hallam Station site for their program dates.

This innovation of lift shafts being constructed off site – which is one of the harder elements of a level crossing removal – has given the LXRP & SEPA Level Crossing a solution to a hard task problem.

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

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Parkville Station will be on the doorstep of Victoria’s world-renowned education, health and research precinct. The Metro Tunnel will enhance access to The University of Melbourne and facilities such as The Royal Melbourne Hospital, The Royal Women’s Hospital and Peter MacCallum Cancer Centre. The new Parkville Station will provide a direct train connection to the area for the first time and relieve pressure on local trams and roads. 

Stilcon scaffolding created stretcher access scaffolding from street level down three levels into the tunnel for the Stilcon Steel team to install the steel walkway required. This stretcher access allowed Stilcon Steel to get their steel and equipment down to all three levels to complete their project.

At street level Stilcon Scaffolding provided support access for the walkway so that both trades and pedestrians could access along east and west of the project area.

Compliant access
As the location was in central Melbourne CBD, the compound for unloading equipment was over 500 metres from the working area. This required additional scheduling and planning of manpower and delivery times.

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

Mentone & Cheltenham Station -12

The Mentone & Cheltenham Station level crossing removal required a 14-metre cut into sand belt land. Stilcon Scaffolding assisted with the restoration of the two heritage listed stations. The design and engineering team designed compliant layher stretcher stairs that could be craned into position and incorporated with the cut of the 14 metres. The stairs were built in four metre sections and the cut was 4 metres below the road level. Stilcon Scaffolding provided bridge scaffold from one side of the cut to the other, spanning approximately 18 metres.

Stilcon Scaffolding and Stilcon Steel worked as a joint venture together on the Mentone & Cheltenham Station, building the stations.

They delivered steel fabrication and construction, scaffolding and plant & equipment. Working together Stilcon Group through their efficiencies of scale were able to deliver this job two weeks ahead of schedule.

To achieve this, the Stilcon Group established their own satellite office to help support and work closely with the SPA team on site.

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

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Stilcon Scaffolding was engaged to work on the Werribee Station & Hoppers Crossing Station level crossing removal in the over road project. The team designed scaffolds to egress and access, as well as safe protection of u troughs of the over road/rails project which spanned from Werribee to Hoppers Crossing. Stilcon Scaffolding supplied riggers for safe access and rescue procedures in the lift shafts for both projects.

The project required the supply of plant & equipment, scaffolding, & riggers. Stilcon Scaffolding also provided rope rescue procedure material, to ensure the job had safe access and procedures in scaffolding into the u troughs and tight spaces around the stations. This also ensured that other trades could complete their works within these spaces.

A unique element of this project was that the rail is very close to the Western Ring Road. 

The scaffolding and the plant & equipment had to work in closely with rail and road, while working on the project, in both occupations and standard day shifts. 

Stilcon Scaffolding was aware of the overheads of the live rail and had to create a design which enabled safely securing the scaffolding away from the high voltage rail overheads.

The Stilcon Scaffolding team (Design, Engineering, Estimator & Operations) worked with McConnell Dowell on the Western Program Alliance (WPA) on a 24/7 basis. This enabled the team to provide real time, immediate solutions when McConnell Dowell needed safe access and solutions working in very tight spaces.

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


Stilcon Scaffolding

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