Reimagining rail infrastructure to improve mobility in Victoria

Picture this. About 53,000 vehicles go through two level crossings daily. The boom gate closure at level crossings at morning peak time causes frustrating delays, traffic congestion, and unreliable travel time for commuters. Additionally, the level crossings pose safety concerns as trains share it with vehicles and commuters. 

That's how the Manchester Road and Maroondah Highway level crossings in Victoria impacted how people lived, worked and traveled. 

The Level Crossing Removal Project 

To address issues caused by such congested and potentially dangerous level crossings across metropolitan Melbourne by the year 2030, the Victorian Government commenced the Level Crossing Removal Project (LXRP), one of the largest rail infrastructure projects of the state to date. 

LXRP involves removing 110 level crossings across Melbourne, upgrading the rail network with new train stations, track duplication and signaling, and adding value to the community with station precincts, for instance, open space, shared use walking and cycling paths, and public artwork. 

Manchester Road and Maroondah Highway are two such level crossings that LXRP has removed, by building rail bridges over the roads, resulting in safer and more efficient transportation.

Delivering the Manchester Road and Maroondah Highway Level Crossing Removal Project  

In 2019, as part of the South Eastern Program Alliance (SEPA), Jacobs was appointed Lead Designer for:

• Removing the level crossing at Manchester Road and building the new Mooroolbark Station, including a new multi-deck car park, doubling car parking to 900 spaces, and easing commuter parking. 
• Removing the level crossing at Maroondah Highway and building the new Lilydale Station. 

Along with Jacobs, the alliance includes Laing O’Rourke (constructor), Metro Trains Melbourne (rail operator) and the Level Crossing Removal Project (project office).

The vision for the new station designs and architectural approach acknowledged the past and present elements of the area. A palette of softer and earthier tones was chosen to complement the low-rise and leafier characteristics of Mooroolbark and Lilydale, and the planting and landscaping plan included indigenous species to connect with local character. 

To bring these projects to life, Jacobs leveraged our global capabilities from experienced building and architecture teams across Australia, New Zealand, the U.K., Malaysia, Poland and India. Our work as lead designer involved track, traction power, rail signaling, and structural and civil design. We also provided specialist inputs that included noise and traffic assessment, flood models, statutory planning, sustainability and safety in design assessment. 

Our Jacobs engineering and architecture team designed the stations collaboratively with design partners BKK Architects, Kyriacou Architects and Aspect Studios Landscape Architects. 

Unlocking lasting, positive outcomes with meticulous planning and innovation 

The project utilized the broader LXRP program of works and adapted design elements, such as the viaduct structural form, known as ‘U’ Troughs. To reduce design timeframes, we used standardized solutions and developed modular solutions for station elements by adapting prior project solutions and modifying them to facilitate off-site pre-fabrication. 

Our work on the projects involved tackling interesting challenges

For instance, there was a tight radius elevated track approaching Mooroolbark Station and a multi-lane road at Maroondah Highway. We adapted standardized bridge forms to achieve the necessary clear spans. 

Lilydale Station had unique requirements. First, it’s a heritage station listed on the Victorian Heritage Register and needed to be preserved. Second, it’s located in a flood-prone area and called for evaluation of future climate change effects on the station. We delivered the project factoring in both aspects – future-proofing it to the impacts of climate change and protecting and repurposing of the heritage structure. 

To enable construction works at Lilydale Station within the available land while also minimizing the impact on the existing Lilydale train stabling, our design team proposed several design innovations associated with track geometry. In addition, our railway signaling work resolved the 'dark territory' problem – track areas without signals or train detection systems - where, previously, it was impossible to monitor vehicles remotely. 

At the Mooroolbark Station, we used a lightweight Ethylene TetrafluoroEtilene (ETFE) transparent polymer roofing, which creates a bright and light-filled entrance and ticketed area. The project prefabricated the lift shafts to enable in-situ lifting and installed an iconic clock tower as part of the project. Considering agricultural and rural connection of the areas, both stations incorporated local stone cladding materials. Both stations have been equipped with lift towers as civic gestures and are connected to footpaths and cycleways.

Both stations have distinctive towers that serve as urban markers. Lilydale Station’s tower is a 27-meter-high (~88.5-foot-high) column topped with LED beacon artwork Wind of Lilydale, a spectacular commission by Turkish-American digital artist Refik Anadol. 

Making travel more accessible and safer, now and for generations to come 

In November 2021, both level crossings were successfully removed, and the new Mooroolbark and Lilydale stations and precincts opened to passengers, improving safety for road users and pedestrians, easing the flow of traffic, and making travel hassle-free and safe for people, leaving a positive legacy for years to come.

These stations were shortlisted for the prestigious 2023 World Architecture Festival awards for completed buildings in the Transport Category, a testament to the entire team's dedication and innovation in transforming travel for the people of Victoria.

In the media

Victoria's Big Build: Level Crossing Removal Project

Victoria's Big Build: Manchester Road, Mooroolbark

Victoria's Big Build: Maroondah Highway, Lilydale

All photos on this webpage courtesy of Peter Bennetts