Projects

Client: Brimble Rail

Project: Full-depth track reconstruction, 600 metres

Possession Window: 51 hours

Corfad Role: Labour, plant, and equipment supply

Overview

When Brimble Rail undertook a 600-metre full-depth track reconstruction, they needed more than just boots on the ground — they needed a contractor capable of working at every level of the operation, from pre-possession planning through to final weld. Corfad Civil & Construction mobilised a comprehensive team of skilled rail labour, high-rail equipment, and specialised plant, delivering their full scope of works within a tight 51-hour possession window and contributing to a seamless, on-schedule outcome.

The Challenge

Full-depth reconstruction is one of the most complex operations in rail maintenance. Every layer of the track structure — rail, sleepers, ballast, and subgrade – is removed and rebuilt, requiring precise sequencing, significant plant resources, and disciplined coordination across multiple trades and contractors.

The 600-metre scope demanded that strip, haul, and build activities run concurrently and in tight sequence. Any delay in one phase had direct consequences for the next. With possession time fixed and non-negotiable, there was no room for poor planning, slow mobilisation, or undercooked resourcing. Everything had to be staged, staffed, and ready to execute the moment the possession was granted.

Corfad’s Scope of Works

Pre-Possession: Planning and Methodology

Corfad’s involvement began well before the possession window opened. The team attended pre-possession T-meetings alongside Brimble Rail and other project stakeholders, contributing directly to the planning and staging of works. Corfad supplied detailed work methodologies for the track build and provided input on the rail stressing plans — ensuring that the sequencing was both safe and achievable within the available timeframe.

This early engagement is characteristic of how Corfad operates. By being part of the planning conversation, the team arrived on site with a clear understanding of the scope, the sequence, and the risks — ready to execute from the first hour.

Pre-Possession Mobilisation: Staging the Site

Before the possession commenced, Corfad’s crews were already on site prepping for the work ahead. High-rail vehicles (RRVs) were used to place new rail along the corridor, positioning it ready for the build phase. Front-end loaders and trucks were deployed to position concrete sleeper bundles at strategic intervals, and lighting towers and additional plant were unloaded and staged to support around-the-clock operations.

Possession — Ballast Cleaner Support

As the ballast cleaner moved through the section, Corfad provided critical support to allow the machine to operate safely and efficiently. RRV operators assisted with cutting the ballast cleaner bar, and Corfad’s welding crews and rail workers cut the track at strategic locations along the corridor. These cuts allowed the rail to expand and creep freely during the cleaning activity – preventing track buckling and keeping the ballast cleaner moving without interruption.

Possession — Track Strip

With the possession underway, Corfad mobilised a substantial strip operation across the 600-metre section:

● 3 RRVs worked in tandem to remove the existing rail, dragging it to a designated stockpile area clear of the work zone

● 2 front-end loaders lifted and removed the concrete sleepers from the formation

● 2 Hydrema hi-rail machines assisted with removal of the underlying soil and formation material

● A water cart maintained continuous dust suppression across the active work area, meeting environmental and safety obligations throughout

● Welders and rail labour worked systematically along the length of the section, unclipping fastenings and cutting the old rail into 110-metre lengths for efficient handling

● Old sleepers were stacked and strapped ready for collection — leaving a clean, prepared formation ahead of the build team

Possession — Track Build

With the strip complete, Corfad’s team moved directly into the build phase, maintaining the project’s momentum through the possession:

● Concrete sleepers were laid using an Octopus attachment, with front-end loaders positioning sleeper stacks efficiently along the formation

● 2 RRVs dragged and placed new rail into the concrete sleepers, with crews following to plate up using Robel rail clamps in preparation for ballasting

● 2 Hydrema hi-rail machines assisted with ballasting as the ballast train moved through the section

● 2 front-end loaders worked to continuously load the ballast train, keeping material supply consistent and preventing hold-ups

● Corfad’s certified welders completed free-welding of the track and carried out final adjustments, bringing the reconstructed section to a standard ready for handback

The Outcome

The 600-metre reconstruction was completed within the 51-hour possession window. Corfad’s contribution — spanning pre-possession planning, site mobilisation, strip operations, and the full track build — was delivered without incident and to the required quality standard.

The result was the product of disciplined planning, experienced crews, and a fleet capable of sustaining high-tempo, multi-phase operations simultaneously. Brimble Rail’s possession was handed back on schedule, with reconstructed track ready for return to service.

About Corfad Civil & Construction

Corfad Civil & Construction is a specialist rail construction and maintenance company operating across Australia. Founded in 2015, the business supplies skilled labour, high-rail plant, and specialised equipment to government rail authorities and Tier 1 contractors.

With 12 certified welders holding qualifications across ARTC, V/Line, MTM, and TfNSW standards, a comprehensive fleet of high-rail vehicles, and Triple ISO certification (9001, 14001, 45001), Corfad brings the depth of capability that complex rail work demands – from a single welding shift to a full possession mobilisation.

Ready to discuss your next project? Contact the Corfad team to talk through your requirements.