Project Overview
Transgrid plays a critical role in Australia’s energy system, operating more than 13,000 km of high-voltage transmission lines and 128 substations across New South Wales, Victoria, and the ACT. As Australia accelerates the transition to a cleaner, more resilient energy system, improving the safety, reliability, and longevity of transmission infrastructure is a core part of the national Rewiring the Nation agenda.
Located in Sydney’s west, Eastern Creek Substation is a key operational asset within Transgrid’s network. As part of ongoing asset maintenance and safety improvements, Transgrid identified the need to replace existing trench covers across multiple trench runs within the substation footprint.
The works were delivered directly by Transgrid within a controlled access, live operational environment, with safety, durability, and long-term performance as primary considerations.
The Engineering Challenge
The existing trench covers consisted of 19 mm solid top grating supplied by an alternative manufacturer and installed approximately seven years earlier. Over time, these covers had deteriorated and were no longer performing as intended, requiring full replacement.
As the trench covers are located at ground level and form part of regular access routes within the substation, the replacement solution needed to address several critical requirements:
- Improved durability and longevity compared to the previous installation
- High slip resistance to ensure safe access for personnel
- Reduced manual handling risk during installation and future maintenance
- Compatibility with existing trench layouts, including varying widths and corner details
Given the operational nature of the site, all works needed to be carried out safely within a controlled access environment, without introducing unnecessary risk to personnel or disruption to substation activities.
A Durable, Safety-Focused Replacement Solution
To meet these requirements, Transgrid selected d² Dura Grating 29mm Solid Top GRP trench covers from Dura Composites Australia as a direct replacement solution across multiple trench cover runs within the substation.
The selected panels were supplied in yellow with a gritted anti-slip surface to provide clear visual identification and enhanced underfoot safety. Panels were sized to suit the existing trench widths, including 690 mm wide runs and larger 1200 × 1200 mm corner sections, allowing installation without the need for on-site cutting.
Compared to the previous trench covers, the d² Dura Grating solution offered:
- Lower weight than competitor trench covers supplied as part of earlier works
- Reduced manual handling risk for installation and future access
- Improved durability and resistance to environmental impact
- An extended warranty and design life compared to the previous solution
Installation in a Live Substation Environment
Installation was carried out directly by Transgrid personnel within a controlled access, operational substation environment. The lightweight nature of the GRP trench covers simplified handling and placement, supporting safer working practices for site teams.
Once installed, the solid top grating provided continuous, secure coverage of trench openings, reducing the risk of trips, slips, and falls, while eliminating the need for ongoing maintenance associated with the previous installation.
Results and Impact
- Replacement of life-expired trench covers across multiple trench runs
- Improved underfoot safety through solid top, anti-slip GRP panels
- Reduced manual handling risk due to lighter-weight construction
- Improved durability and longevity compared to the previous solution
- Maintenance-free trench cover solution in a live substation environment
- Enhanced safety for personnel working across operational access routes
Supporting Australia’s Energy Transition
By investing in safer, longer-lasting infrastructure within its substations, Transgrid continues to support the resilience and reliability of Australia’s transmission network. Practical interventions such as the Eastern Creek trench cover replacement play an important role in enabling the broader Rewiring the Nation programme, helping ensure the network is fit for purpose as renewable generation and demand continue to grow.
Testimonials
We’ve been extremely impressed with the quality of these products — they far exceed what we were previously using. Rakuji went above and beyond, answering all my technical questions and spending time on-site to ensure we received a solution that would suit our needs and last well into the future. On top of that, these products are cheaper and lighter than competitor GRP options, and deliver significant cost and weight savings.
Luke Morris, Senior Program Specialist, Transgrid
