Projects

Client: UGL Project: Parramatta Light Rail – Stage 1

Location: Western Sydney, NSW

Services Provided: Rail welding, support crews, plant hire, innovation delivery, sustainability initiatives

Duration: 2023–2024

Overview

The Parramatta Light Rail is a flagship NSW Government project designed to deliver fast, reliable, and accessible public transport to one of Sydney’s fastest-growing regions. Corfad was proud to be selected by UGL as a trusted partner for the delivery of Stage 1, providing a full suite of specialised services including rail welding, high rail plant hire, track labour, and innovative solutions to project challenges.

Scope of Works

Corfad’s responsibilities included:

• Rail welding (aluminothermic and flashbutt)

• Labour hire: weld supervisors, rail welders, offsiders, labourers, and track supervisors

• High rail plant hire and logistical support

• Workforce scaling to match possession schedules and construction phases

• Innovation development to improve safety and efficiency

At peak times, 53 crew members from Corfad were deployed to the project. We managed this scaling seamlessly to align with our client’s evolving site requirements and timelines.

Innovation in Action

1. Acco Drain Cutting Innovation.

A major safety concern was the traditional use of 7” and 9” grinders to cut Acco drains within the light rail structure. Corfad designed, trialled, and successfully implemented a new custom-cutting process that:

• Eliminated the high-risk use of grinders

• Increased output from 4 to 12 holes per crew per day

• Allowed cutting even after rail was encased in concrete This innovation significantly enhanced crew safety, quality, and productivity, setting a new benchmark for similar rail construction activities.

2. Gauge Grinding Solution.

Corfad also collaborated with the client to resolve issues with gauge changes after concrete encasement, particularly around tight-radius curves. Our team:

• Designed a new gauge grinder

• Secured a TOC Waiver for use on the TfNSW network

• Delivered a solution that achieved certification-ready standards and solved a previously unresolved issue for our client

Workforce Development & Social Inclusion

Corfad is committed to long-term workforce development and inclusion. On this project, we:

• Exceeded internal targets for upskilling crew into certified welders, track certifiers, and supervisors

• Surpassed diversity goals, including:

◦ Female participation in non-traditional roles

◦ Engagement of workers under 25

◦ Inclusive employment and training pathways for both Indigenous and non-Indigenous workers These efforts supported long-term employment outcomes and enhanced project capability.

Environmental Stewardship

Corfad integrated sustainability into every aspect of our delivery. Working collaboratively with UGL, we:

• Monitored and tracked fuel use and sustainability metrics

• Enabled biofuel usage where possible

• Separated waste streams to optimise recyclable materials

• Focused on reducing our environmental footprint, both for internal operations and in support of the client’s broader environmental goals

Outcomes

• Safety: Zero major incidents recorded

• Productivity: Tripled output in key high-risk tasks through innovation

• Compliance: Delivered TfNSW – approved solutions

• Sustainability: Implemented low-impact practices and waste minimisation

• Diversity & Skills: Developed a stronger, more inclusive, and highly skilled workforce

Conclusion

Corfad’s involvement in the Parramatta Light Rail – Stage 1 project demonstrates our ability to deliver on safety, innovation, environmental responsibility, and workforce excellence. Through deep collaboration, problem-solving, and forward-thinking, we supported UGL in delivering a major infrastructure project that will serve Sydney’s west for generations to come.