METRONET C-series Delivery & Bellevue Railcar FacilityDesigning and delivering the great Western Australian train revival 

Aurecon collaborated closely with Public Transport Authority (PTA) to derive and define the requirements – for technical specifications, maintenance performance attributes, and assimilating applicable standards – to inform the tender schedules for both the Electric Multiple Units (EMU) and Diesel Multiple Units (DMU) procurement.

This included a comprehensive review of industry best practice in DMU railcar design and a meticulous, diligent and logical compilation of relevant rail standards (RISSB, DSAPT, AS, and international standards) to bridge regulatory gaps and ensure system-wide compliance.

As the Lead Technical Advisor during the tender evaluation/assessment phases of the procurement, Aurecon facilitated commercially sensitive technical interactions between supplier proponents and the PTA. This included evaluating submissions and providing technical support on requirements queries, change of requirements, and managing interfaces between the supply chain and the PTA during the project execution phase (design, manufacturing, testing, and commissioning).

Located on a 400,000 m² site, the Bellevue facility supports full lifecycle manufacture, maintenance, and overhaul infrastructure for both EMUs and DMUs, and accommodates:

• Dual-gauge railcar manufacturing facility
• High-voltage test centre for new train testing
• Sign-on facility providing administrative, amenity, and training functions for drivers
• Whole-of-life EMU maintenance centre for a fleet of up to 100 railcar sets
• EMU external and internal wash facilities
• Dual-gauge diesel maintenance facility for the whole-of-life overhaul needs of standard and narrow-gauge fleets
• DMU wash plant
• Mixed-gauge overhaul centre with a dual-gauge wheel lathe and bogie drop facility.

Aurecon worked closely with the PTA to take the project through the business case, land use planning and development approvals before developing concept and construction ready detailed designs. Aurecon, in collaboration with sub-consultant partners (Plus, Urbis and RLB) delivered a fully integrated design, including:

Design of all elements of the industrial buildings including mechanical, hydraulics, fire, structure, architecture, communications, security, civil works and internal infrastructure.

Design of the permanent way having an interface with the operational tracks.

Design of all drainage works including drainage basins, storm water drainage, roads, carparks, hardstands, security and other utilities.

Compliance to the PTA EM4P, specifically the engineering assurance of the design.

Aurecon continues to support the PTA through construction support and oversight for all site matters on the Stage 2 multifunctional maintenance and stabling areas.

To meet the delivery requirements, Aurecon implemented a strategic approach that diversified the rail component supply chain. The Perth C-series comprises significant localised content, with assembly of all componentry and manufacture of bogie frames being undertaken in Perth. By engaging a broad spectrum of local suppliers, the project ensured key components, such as seating and bogies, were sourced from within Western Australia.

This strengthened the local manufacturing sector and mitigated risks associated with supply chain disruptions. For instance, the seat cushion supplier, which serves multiple industries, completed the production run of upholstered seat covers within six months, allowing for efficient storage and timely deployment.

Aurecon's expertise has significantly bolstered Western Australia's local economy by prioritising local supplier engagement and fostering sustainable employment.

Additionally, the C-series trains are produced at a deliberately conservative rate of approximately six trains (each comprising six cars) per year. This steady production pace is complex and challenging, yet it is designed to maintain a consistent employment baseline, providing sustained job opportunities for the local workforce. Also, by integrating the C-series production into a diverse product base, suppliers are not solely reliant on this project, enhancing their resilience and capacity.

Through these and other initiatives, the project has surpassed local content objectives, delivering tangible economic benefits to Western Australia.

Turning a legacy site into a sustainability benchmark

Sustainability and resilience were critical to the successful delivery of the Bellevue Railcar Manufacturing and Maintenance Facility. Faced with a site laden with 130,000 cubic metres of boiler ash, a lack of ground porosity, and 12 metres of impermeable clay, Aurecon designed an integrated geotechnical and drainage solution that ensured safe operations, saved over $2 million, and avoided transporting and disposing of approximately 80,000 cubic metres of boiler ash and contaminated soil.

With no available geotechnical or environmental investigation data at project inception and limited site access, Aurecon progressed design to 85 per cent before physical testing could begin. Once on-site, Aurecon’s team identified an opportunity to stabilise and repurpose the boiler ash. Collaborating with PTA, Aurecon developed a scientifically informed, value-engineered earthworks strategy that exceeded Western Australia’s sustainability targets, recycling over 85 per cent of earthworks material, with at least half reused on site.

Rich in carbon and trace elements, the boiler ash was incorporated into a soil mix that improved water and nutrient retention and enhanced the site’s microflora and fauna. Aurecon’s innovative, science-led approach turned an environmental liability into a benchmark for sustainable infrastructure design. The solution flipped a regulatory challenge into an opportunity for environmental leadership and is an example of how Aurecon’s design-led thinking transforms constraints into innovation.