Project Overview
Sydney Metro is Australia’s largest public transport project, designed to transform the city’s rail network with state-of-the-art stations and improved connectivity. As part of the Sydney Metro Waterloo Station development, Anchor Safe Rope Access was engaged to provide confined space expertise for critical safety and infrastructure installations in one of the most high-risk environments we have ever encountered.
Scope of Work
Working in highly restrictive underground environments, our rope access team successfully contributed to the installation of:
- Safety grates for improved worker protection
- Communication lines & optical fibre to support the station’s advanced network system
- Fire protection systems, including smoke detector installation and fireproofing repairs
- Electrical infrastructure, including reconnecting earth cables to cable trays
- Anchor installations into the concrete adjacent to high-voltage cables
- Extensive confined space entry and rescue planning to ensure safety compliance
- Remedial works to remove “Coil Tie Cones / Z-Bar Cones” from concrete substrate and fill voids with fire-rated concrete filler
- Concrete void filling and defect repairs to structural concrete sections
- Removal and cleaning of foam residue from structural concrete sections
High-Risk Work & Safety Planning
This project involved significant risk mitigation due to extremely hazardous conditions, including a confined workspace limited to approximately 1,500mm² and the presence of high-voltage cables exceeding 20,000V that powered the metro system. These cables could not be deactivated, meaning any accidental contact with the drill during anchor installations could have resulted in fatal consequences.
Recognising these extreme risks, our IRATA Level 3 specialists developed a fully operational external rescue plan, which was rigorously assessed and approved before work commenced. Every aspect of the project was meticulously planned to ensure absolute compliance with Sydney Metro’s stringent safety protocols.
Remedial Works Execution
To ensure the integrity and fire safety of the concrete structures, our rope access technicians carried out extensive remedial works, including:
- Removal and filling of “Coil Tie / Z-Bar Cones” from the confined space shaft walls
- Technicians used a metal fixing rod to pry and dislodge the cones
- The voids were thoroughly cleaned to remove loose material and contaminants
- Fire-rated masonry filler (supplied by Boral) was securely applied, smoothed, and levelled with the substrate
- Filling of concrete voids and defects in structural sections
- Defective areas were cleaned to ensure optimal adhesion
- Fire-rated masonry filler was applied to prevent air lockage and ensure durability
- Removal and cleaning of foam residue from structural concrete sections
These remedial works were executed with strict safety protocols, with two rope access technicians operating inside the confined space and a third technician stationed outside to manage emergency rescue and material supply.
Challenges & Solutions
- Confined Space Access: The small workspace required specialised rope access techniques and careful coordination to ensure safe manoeuvrability.
- High-Voltage Hazards: Strict procedures were followed to prevent any accidental contact with the 20,000V cables, ensuring safe completion of anchor installations.
- Comprehensive Safety Planning: The custom-designed rescue plan ensured that in the event of an emergency, an immediate and effective response was in place.
Results
Anchor Safe Rope Access successfully completed the installation without incident, despite the extremely high-risk conditions. Our commitment to safety, precision, and expertise ensured that all work was executed efficiently while maintaining the highest industry standards. This project stands as a testament to our ability to manage and execute complex, high-risk confined space projects with unwavering safety and professionalism.
