Locomotive maintenance has traditionally relied on ladders, harnesses, and temporary access methods to reach the top of trains. While common, these approaches are often slow to set up, difficult to manage in busy workshop environments, and introduce unnecessary safety risks for maintenance teams.
At KiwiRail’s Waltham Mechanical Hub, the challenge was clear:
to provide a safer, more efficient way for their team to access locomotive roofs—without the ongoing complexity of harness systems or scaffolding.
The Challenge
Working at height on locomotives requires frequent access across long roof spans, often in tight and active workshop environments. Traditional solutions limited movement, increased setup time, and made it harder to maintain consistent safety controls across teams.
KiwiRail needed an access solution that would:
- Remove reliance on harnesses
- Improve safety and stability for workers
- Increase efficiency during routine maintenance
- Integrate seamlessly into an operational workshop
The Solution: A Bespoke Cantilevered Access Platform
To meet these requirements, we designed and delivered a Cantilevered Hoop Guardrail Platform tailored specifically to KiwiRail’s rolling stock and workshop layout.
The bespoke solution includes:
- A 1m² cantilevered deck providing safe access over the train roof
- Full surround guardrails (top and mid rails) to create an enclosed working area
- A telescopic stabilising brace that rests directly on the roof of the train, increasing stability during use
- A mobile design that rolls easily into position and winds down securely once in place
This configuration allows mechanics to access and move across the roof of locomotives safely, without the delays, restrictions, or risks associated with temporary access systems.
Hear it firsthand from Tim Johns at KiwiRail
👉 Watch the video here:
The Result
This custom access platform has transformed roof-level maintenance at the Waltham Mechanical Hub.
The outcome includes:
- Reduced reliance on PPE-heavy systems
- Faster setup and repositioning between jobs
- Improved safety and confidence for maintenance teams
- A more streamlined and efficient workflow
By investing in a purpose-built access solution, KiwiRail has improved both safety outcomes and day-to-day operational efficiency.
Talk to Our Industry Experts
Every site, asset, and maintenance environment is different. Off-the-shelf access solutions don’t always deliver the safest or most efficient result.
If your team is facing access challenges at height, talk to our industry experts today about a bespoke access solution designed specifically for your operation, your equipment, and your people.
