Enhancing Rail Worksite Safety through Innovative Technology

Enhancing Rail Worksite Safety through Innovative Technology
How McDonald Surveys Improved Safety for Machine Operators on the Pilbara Rail Project

Overview

For McDonald Surveys, safety was the top priority on the Pilbara Rail Project with Rio Tinto. The core challenge was to elevate worksite safety standards while maintaining project deadlines and operational accuracy. Leveraging the Trimble Earthworks system and a custom octopus excavator attachment, the team at McDonald Surveys successfully reduced worker-machine interactions, enhanced the precision of rail sleeper installation, and streamlined their operations across the rail project.

McDonald Surveys

McDonald Surveys is a multidisciplinary surveying and engineering firm specialising in digital engineering, 3D modelling, and maintenance support. With a strong focus on client collaboration and cutting-edge technology, the company delivers efficient, safe, and compliant project outcomes across Australia’s rail, road, and infrastructure sectors, consistently optimising project timelines.

Their service offerings include brownfield and greenfield surveying, rail design, machine control support, and shutdown planning all designed to enhance precision and efficiency in complex civil and rail operations.

Pilbara Rail Network Project

The Rail Network Project in the Pilbara region of Western Australia encompasses 1,900 km of track and supporting infrastructure. The network services 17 iron ore mines and four port terminals, with up to 35 trains operating daily.

Maintenance and upgrade requirements involve carefully planned rail shutdowns. Unlike typical rail closures scheduled during off-peak times, shutdowns in the Pilbara often occur during active mining operations. These closures can last from 36 to 240 continuous hours, involving intensive day and night shifts, and demanding close collaboration between clients, contractors, and rail control regulatory bodies to ensure safety and efficiency.

Support from the survey team was fundamental at all stages, including pre-design, pre-project execution, during project execution and post-handback during follow-up tamping stages.

Identifying Safety Hazards on Site

Machine operators are required to always remain vigilant to the hazards and risks of the project. For the Pilbara Rail Project in particular, it was essential that operators were aware of their surroundings, their machine, and their work and that they maintained accurate levels throughout the project.

The main risks during sleeper installation included:

Uncontrolled energy release
Lifting operations
Rail collisions and operations

Working in proximity to mobile plant
Operation of plant and equipment

To mitigate these risks, workers were required to perform constant visual checks of their surroundings and ensure they remained attentive and reactive to radio communication, all while their machine was in continuous operation. This high-pressure environment demanded constant, peak performance from every person on site.

The Solution:

Integrating a Custom Attachment with Advanced Machine Control

To improve operational accuracy and safety, the team integrated a custom “octopus” excavator attachment with the Trimble Earthworks System. Unlike a standard bucket, the octopus attachment required a completely custom machine file definition to function within the Earthworks environment.

The integration was engineered to meet several critical performance and safety criteria:

Minimised installation time and precise alignment of sleepers to the digital design model

Clear operator visibility of both the attachment and work area

A seamless workflow with no interruptions and improved task clarity and coordination for the ground crew

The Outcome:

A Step-Change in Safety and Efficiency

The successful integration of the custom octopus attachment with Trimble Earthworks delivered transformative results for the Pilbara Rail Project. Most importantly, the solution dramatically improved worksite safety. By automating the placement of sleepers, the system significantly reduced the need for ground crews to work in close proximity to active machinery, mitigating one of the project’s primary risks.

This automation also delivered a step-change in operational efficiency. The GNSS-guided attachment placed each sleeper with exceptional precision, eliminating guesswork and reducing manual labour requirements. This streamlined workflow allowed the team to meet demanding shutdown schedules and set a new standard for productivity on the project.

Technology Driving Safety

The commitment to safety on the Pilbara project went beyond new equipment; it was about actively using technology to solve real-world challenges identified by the crew. A prime example of this was the revision of on-site survey layouts. Based on direct operator feedback, McDonald Surveys collaborated with the team to relocate the Machine Guidance Total Stations (SPS930) and Surveying Conformance stations (S9, SX12).

These essential tools were strategically moved to safer areas that still maintained a clear line-of-sight to work zones and control points. This simple but critical adjustment significantly reduced the need for personnel to work near active machinery, directly addressing a key site hazard. This proactive, collaborative approach was exactly what the client valued.

“Our client continually challenged us to prioritise safety by leveraging technology and delivery solutions not only with precision but also to reduce the interaction between people and plant”.

This on-the-ground innovation was supported by a comprehensive digital ecosystem, including Trimble Business Centre for data preparation, and WorksOS and Works Manager for real-time project oversight, creating a truly connected and safety-focused worksite.

Collaboration as a Cornerstone

The deep collaboration between McDonald Surveys and Rio Tinto, rooted in a shared commitment to safety, created a worksite centered on technological innovation. The successful deployment of Trimble Earthworks with a custom attachment not only solved an immediate challenge but now stands as a new benchmark for safety and efficiency in rail infrastructure.

Project partners included Rio Tinto, Pilbara Rail Maintenance, McDonald Surveys, SITECH, Trimble, and UPG. Together, these businesses demonstrated how thoughtful integration of technology, design, and teamwork can set new standards in worksite safety and efficiency, producing more effective results across rail projects.

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