The Level Crossing Removal Project has marked a major milestone, with the installation of its 1000th U-trough – an engineering innovation that has become key to many removals of dangerous and congested level crossings across the state.
The 1000th U-trough was recently installed west of Coburns Road as part of the Melton level crossing removal project. To mark the milestone, crews created a stencilled memento in recognition of the 1000s of workers who have helped deliver and install these mammoth concrete segments on projects across Melbourne.
U-troughs are precast concrete structures that form the superstructure for elevated rail bridges, allowing trains to run above roads, freeing up space for new uses below the rail line. In an Australian first, the U-troughs have been designed specifically for the Level Crossing Removal Project and are now widely used across Victoria’s Big Build.
Since their introduction on the Mernda Rail Extension in 2018, U-troughs have become a defining feature of Victoria’s level crossing removals.
Their use in level crossing removal projects in Brunswick and Coburg, Preston, Pakenham, Parkdale and Carrum has helped to create more than 20 MCGs of open space for community facilities, playgrounds, and cycling and walking paths, and 1000s of new trees and hundreds of thousands of new plants, shrubs and grasses.
Deputy Program Director Ian Ransley played a key role in the decision to use U-troughs and was on the ground for the installation of the first one at Mernda.
Ransley said the design solution delivered fantastic engineering and community benefits, making the rail network safer and quieter, and transforming the way people live, work and travel.
The U-troughs, made up of 2 massive L-shaped concrete beams, are installed on top of crosshead piers and then ‘stitched’ together to form a U-trough. All the U-troughs have been manufactured in regional Victoria, supporting local jobs for more than eight years.
Senior Project Engineer Ben Bartlett, who was on site for the installation of the 1000th U-trough at Melton, said it was amazing to see them used in so many places to remove level crossings.
“It’s a really impressive legacy that I have been able to contribute to. It’s certainly something I will be taking kids back to in the future to show them what a wonderful thing I have worked on,” he said.
Construction is underway in Melton, with all 4 boom gates set to be removed and the new Melton Station to open in 2026, 2 years ahead of schedule.
With more elevated rail projects underway – including works at Newport and Mordialloc – and more in the pipeline, the U-trough will continue to play a key role in transforming transport hubs and local communities as we move closer to achieving our commitment to remove 110 level crossings across Melbourne by 2030.