Redefining track slab construction

RSRG’s in-house designed and built Tunnel Concrete Placement Units (CPUs) were developed to solve a long-standing challenge in track slab construction: how to safely and efficiently place and finish concrete in constrained linear work fronts.

Traditionally, track slab construction relies heavily on manual processes, with workers standing on sleepers or temporary platforms while manoeuvring concrete delivery pipes and hoses and finishing concrete in conventional positions. This method does not adequately manage inherent safety risks and makes it difficult to achieve consistent quality and production rates.

In response, RSRG built the Tunnel CPUs specifically for the Cross River Rail project in Australia. Designed as a self-propelled multi-carriage system, the CPU enables continuous concrete placement through an integrated distribution system, reducing the need for manual handling of concrete pipes.

Low-level, full-width working platforms provide a stable and ergonomic environment, improving safety, reducing fatigue and enhancing productivity. The result is a step change in quality and efficiency, with the Tunnel CPU proving its value as a reliable, high-performance solution in tunnel or constrained environments.

Building on this success, RSRG adapted the concept for the Sydney Metro – Western Sydney Airport project.

This next evolution, the “Outdoor CPU”, was designed for open-air environments where variable weather affects track slab construction. Maintaining the same principles of safety, efficiency and quality, it extends the benefits of the original design beyond tunnels, enabling consistent delivery across a wider range of conditions while providing an optimised working environment.

Through continuous refinement, RSRG has addressed a critical logistical challenge in the rail industry and set a new benchmark for track slab construction.