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UGL Rail
UGL Rail
UGL Rail
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UGL Rail is an Australian rail company specialising in building, maintaining and refurbishing diesel locomotives, diesel and electric multiple units and freight wagons. It is a subsidiary of UGL and is based in Melbourne, with a staff of 1,200 across Australia and Asia. It operates factories in Broadmeadow (Newcastle), Spotswood and Bassendean. While it used to operate a factory in Taree, the plant was shut down and the equipment sold off.

Key Information

History

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Pacific National NR class
New South Wales 43 class
NSW TrainLink H set
Sydney Trains C set
New South Wales Hunter railcar
Hong Kong Light Rail Phase III LRV

Founded in Australia in 1899 by Cornish brothers Alfred and Ralph Goninan as an engineering and manufacturing company for the coal industry, A Goninan & Co Limited was incorporated as a public company in 1905.[1]

It entered the rail business in 1917 via Commonwealth Steel Products Company of Waratah, Newcastle, a wheel and axle manufacturer, because those items could no longer be imported from Belgium due to World War I. A Goninan & Co moved to more convenient freehold land at Broadmeadow in 1919 and built a flourishing business in general engineering.[1] It made pitheads, boilers, wagons and a huge, cast 41-ton block for the district's coal trade.[1] In October 1964, A Goninan & Co was purchased by Howard Smith.

In August 1999, A Goninan & Co was sold to United Group and re-branded United Goninan.[2] In 2005, it was renamed United Group Rail, as part of a reorganisation following United Group's purchase of Alstom's Australian subsidiary, Alstom Transport Australia and New Zealand.[3]

Factories

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While most items were manufactured at Broadmeadow, it did purchase Comeng's Bassendean, Western Australia plant. This plant rebuilt many Pilbara Alco locomotives with General Electric components in the 1990s as well as building 17 Westrail P class and 60 NR class locomotives.[4]

In 1983, a factory was established in Townsville to fulfill a contract for Queensland Railways 2600 class locomotives that required them to be built locally. It later built the 2800 class.

As part of UGL's acquisition of Alstom Australia and New Zealand in 2005, UGL leased Alstom's workshops at Ballarat North from then until 2012.[5][6]

Products

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National

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New South Wales

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Victoria

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Queensland

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Western Australia

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Hong Kong

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New South Wales

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Sydney Metro

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UGL is a part of Metro Trains Sydney which constructed and now operates the Sydney Metro Northwest[7]

New Intercity Fleet

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UGL is a member of the RailConnect NSW consortium, a joint venture between UGL, Hyundai Rotem and Mitsubishi Electric, which has designed and will build and maintain more than 500 NSW TrainLink D set train carriages. Delivery commenced in the second half of 2019. Maintenance will be carried out at the Kangy Angy Maintenance Centre.[8]

UGL Unipart

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UGL Rail has been responsible for the maintenance of all of CityRail's EMU fleet at Maintrain, Auburn since March 1994 following the closure of Electric Carriage Workshops and Eveleigh Carriage Workshops.[9] In the early 1990s, A Goninan & Co refurbished S and V sets at Broadmeadow as part of the Citydecker program.

Since December 2011, UGL Unipart, a 70:30 joint venture with Unipart, has maintained most of CityRail and later Sydney Trains and NSW TrainLink's EMU fleet.[10]

Maintenance on H sets was initially carried out at Eveleigh but from 2018 is done at other depots with major work done at Maintrain, Auburn[clarification needed] as for other types of Sydney Trains sets. The contract to maintain 1,050 Sydney Trains carriages including H and V sets was extended for two years from 1 July 2019.[11]

Country Regional Network

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UGL Rail has been responsible for maintaining the NSW Country Regional Network since January 2022.[12][13] It took over from John Holland Group.

Metro Trains Melbourne

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UGL Rail owns 20% of Metro Trains Melbourne, the consortium that has run Melbourne's metro railway network since November 2009.[14]

Adelaide

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In July 2020, UGL Rail became responsible for maintenance of the Glenelg tram line in Adelaide as part of the Torrens Connect consortium.[15][16]

See also

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References

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Revisions and contributorsEdit on WikipediaRead on Wikipedia

UGL Rail

View on Grokipedia
from Grokipedia
UGL Rail is an Australian division specializing in the design, manufacture, maintenance, and refurbishment of diesel locomotives, diesel and electric multiple units, and rail infrastructure, providing end-to-end solutions for and freight rail sectors as part of UGL Limited, a of (pending sale of the transport division to in late 2025 or early 2026). UGL Rail traces its origins to A. Goninan & Co, founded in 1899 by Alfred Goninan to support the coal industry in , which was acquired by UGL Limited (established 1970) in 1999 and rebranded as UGL Rail, evolving into a diversified entity over 125 years. UGL Rail has grown to become Australia's largest provider of and solutions, emphasizing Australian-designed and manufactured products, including the of over 3,000 rail passenger cars and the integration of advanced technologies like train control systems. The division operates across the region, delivering services such as , operations support for networks, and innovative projects including driverless metro systems, six-car automated trains, and with gap fillers. Notable engagements include the operations and maintenance of the Country Regional Network for , the franchise, and contributions to the project in , underscoring its role in enhancing efficiency and safety.

History

Founding and Early Expansion

A. Goninan & Co. Limited was established in 1899 by brothers Alfred and Goninan in Wickham, near , as a general and boilermaking firm primarily serving the local industry. The company began with a small workforce fabricating equipment such as coal skips and agricultural implements, quickly securing its first major rail-related contract in 1900 for 100 eight-ton coal wagons destined for Rhondda Colliery. Incorporated as a in 1905, the firm expanded its operations amid Newcastle's industrial growth, employing around 90 workers by 1902 and diversifying into structural projects. The company's entry into the broader rail sector occurred in 1917, prompted by World War I disruptions that halted imports of essential railway components like wheels and axles from overseas. To address this shortage, Alfred Goninan co-founded Commonwealth Steel Products Co. Ltd. at Waratah, enabling local production of these critical parts and securing initial contracts for railway wagon manufacturing and component supply. In 1919, Goninan acquired a larger site at Broadmeadow, a former smelter, which became the hub for its expanding operations and was praised by 1923 as one of the best industrial layouts in the Commonwealth. By , the firm had deepened its rail involvement through the production of locomotive boilers and undertaking repairs for , supporting Australia's growing rail network during the . Post-World War II industrialization drove significant expansion, with Goninan transitioning from steam-era support to modern diesel technology in the 1950s. The company began constructing diesel-electric locomotives in the 1950s, delivering its first units to Newcastle Steelworks in 1954. In 1956, it delivered six 43-class units to the under license from the , marking a pivotal shift toward powered rail vehicles. These 1,600 horsepower models were designed for branchline and shunting duties, exemplifying Goninan's growing expertise in diesel assembly. By the 1960s, the Broadmeadow facility had evolved into a comprehensive repair and maintenance depot, handling overhauls for industrial locomotives such as the BHP Newcastle 37 class, introduced in 1960, and solidifying the company's role in Australia's rail infrastructure amid rapid economic development. This organic growth positioned Goninan as a foundational player in domestic rail manufacturing through the mid-20th century. In 2024, UGL Rail celebrated its 125th anniversary, highlighting the legacy of Goninan's contributions to Australian rail manufacturing.

Acquisitions and Rebranding

In 1999, United Group acquired A. Goninan & Co., a longstanding Australian rail manufacturer, integrating its rail division into the group's operations and renaming it United Goninan Limited. This acquisition marked United Group's entry into the rail sector, leveraging Goninan's expertise in rolling stock production to expand capabilities in engineering, construction, and maintenance services. By 2005, following the acquisition of Alstom's transport business in and , the rail division underwent further reorganization and was rebranded as United Group Rail. This move consolidated operations, enhancing United Group's position as a leading provider of rail supply, , and across the region. The rebranding reflected broader corporate expansions, including the integration of Alstom's facilities and workforce to streamline project delivery in sectors like rail and resources. Key operational shifts included the closure of the Taree manufacturing plant in 2013, with production and resources redirected to the Broadmeadow facility in Newcastle to improve efficiency. In 2012, the rail division was rebranded once more to , aligning with the parent company's name change from to UGL Limited earlier that year. This period also saw the expanded utilization of legacy assets, such as the former Comeng Bassendean plant in , which bolstered heavy maintenance and rebuilding operations for locomotives post-1999. In 2016, CIMIC Group—formerly Leighton Holdings—acquired UGL Limited in a $524.5 million takeover, leading to the company's delisting from the Australian Securities Exchange on January 3, 2017. By this integration into UGL's structure under CIMIC, the rail division achieved greater alignment with global engineering services, focusing on specialized rail projects. These changes resulted in workforce consolidation, emphasizing rail specialization and operational efficiency across Australian sites.

Ownership and Organization

Parent Company and Corporate Structure

UGL Rail operates as a key division within UGL Limited, which has been a of the since its acquisition in December 2016 for A$524 million. As part of this structure, UGL Rail focuses on rail , , and operations, contributing significantly to UGL's broader transport sector that encompasses engineering services in rail, energy, and resources. The division is headquartered in North Sydney, New South Wales, , supporting its primary activities in Australian rail networks while maintaining residual ties in . The corporate governance of UGL Rail falls under the oversight of UGL Limited's board, led by executives such as Managing Director Doug Moss, who emphasizes integrated engineering solutions across sectors. This structure aligns with CIMIC's strategic focus on diversified infrastructure services, where UGL's transport operations play a central role in delivering end-to-end rail solutions. Prior to the ongoing 2025 sale process, UGL's transport sector, including the rail division, generated annual revenues of approximately $1.5 billion to $1.9 billion, with earnings before interest and taxes exceeding $100 million. In July 2025, CIMIC initiated the divestment of this business unit, advised by Macquarie Capital, with final bids expected in October; as of November 17, 2025, ACS (CIMIC's parent) has agreed to sell UGL's transportation business to Japan's Sojitz Corporation for over 560 million euros (approximately A$920 million), subject to regulatory approvals and expected to close by the end of 2025 or early 2026, potentially altering UGL Rail's independence within the group. UGL Rail employs around 1,200 staff dedicated to its operations across , supporting sites, depots, and project delivery. This workforce underpins the division's role in sustaining CIMIC's portfolio amid the evolving corporate landscape.

Subsidiaries and Joint Ventures

UGL Regional Linx serves as the primary operational entity for the of ' Country Regional Network (CRN), a contract awarded to UGL by in 2022 for a 10-year period covering operations and infrastructure upkeep. This arrangement encompasses responsibility for 2,386 kilometers of operational and freight rail lines, along with 3,139 kilometers of non-operational lines, facilitating the safe of people and goods across regional areas. As part of its scope, UGL Regional Linx oversees the Mindyarra Maintenance Centre in , which was completed in 2025 and now supports ongoing train servicing for the regional fleet. In partnership with Rail, UGL established UGL Unipart Rail Services Pty Ltd, a 70:30 focused on heavy , component supply, and for Sydney's metropolitan passenger rail fleet, servicing over 1,050 cars under contracts with . This collaboration has enabled successful bids for large-scale agreements, including a five-year extension in 2019 valued at approximately A$630 million, leveraging UGL's local expertise and Unipart's global capabilities. UGL holds a 20% stake in the Metro Trains Melbourne consortium, formed in 2009 with (60%) and (20%), to manage operations and maintenance of Melbourne's metropolitan rail network spanning 390 kilometers and 218 stations. This ongoing involvement has supported extensions to the franchise, including a 2024 renewal, contributing to network improvements and passenger services since the consortium's inception. Historically, UGL maintained a presence in through its broader operations, which were wound down in amid challenges in securing new business, though this did not directly impact its core rail activities. In 2025, UGL Regional Linx expanded its CRN responsibilities to include the Wumbulgal rail siding project, a A$13 million initiative in partnership with to construct a 1,500-meter multi-user siding between Griffith and Leeton, with construction from July to November to enhance freight efficiency.

Facilities

Australian Manufacturing Sites

UGL Rail maintains three primary manufacturing facilities across , each contributing to the design, assembly, and production of rail vehicles tailored to national and regional needs. These sites support the company's role in delivering locomotives, passenger cars, and related components, leveraging specialized infrastructure for heavy engineering tasks. The Broadmeadow facility in , stands as UGL Rail's flagship manufacturing site, with roots tracing back to A. Goninan & Co., which relocated its operations to Broadmeadow in 1919 after establishing the business in 1899 to serve the local coal industry. This site has evolved into a hub for locomotive assembly, producing advanced diesel-electric models such as the Evolution Series Evo locomotive unveiled in 2025. It is also renowned for fabricating passenger , including the iconic Tangara trains originally built there in the 1980s and 1990s. The facility's long-standing presence underscores its historical significance in Australian rail manufacturing, marked by a centennial celebration in 2019 for over 100 years of continuous operation under Goninan and its successors. In , Victoria, the Spotswood factory bolsters UGL Rail's southern operations, acquired in through the $267.5 million purchase of Alstom's Australian and New Zealand transport business, which included key workshops and expertise in rail vehicle production. This acquisition expanded UGL's capacity for passenger vehicle fabrication, enabling the site to contribute to Victorian rail initiatives by integrating Alstom's established manufacturing processes for electric multiple units and components. The facility's strategic location near major transport corridors has positioned it as a vital asset for assembling and customizing to meet state-specific requirements. The Bassendean facility in Perth, , supports western regional builds and was established as part of UGL's expansion into the state more than 30 years ago, initially focusing on rail and sector components. It handles the production of locomotives and wagons adapted for Australia's resource-heavy freight networks, including recent assemblies for local operators. In April 2024, UGL secured a A$110 million contract with ADCO Constructions to construct a new maintenance plant at nearby Bellevue, enhancing the site's overall infrastructure for integrated manufacturing and support activities. Historically, UGL Rail operated additional sites to meet demand, including a factory in , , established in 1975 for wagon and component production, which closed in October 2013 amid shifting workloads and resulting in over 130 job losses. The company also leased the Ballarat North Workshops in Victoria from 2005 to 2012, utilizing the 5.5-hectare site for rail vehicle overhauls following the acquisition, before returning operations to upon lease expiration. These sites collectively employ skilled tradespeople in and assembly, enabling comprehensive production capabilities across diesel and electric rail technologies.

Maintenance and Operational Depots

UGL Rail maintains a network of specialized depots across dedicated to the repair, testing, and operational support of rail vehicles, distinct from its primary manufacturing sites. These facilities enable comprehensive heavy maintenance activities, including bogie overhauls, wheel lathe operations, and advanced diagnostic technologies, supporting fleet reliability for various operators. Until July 2024, UGL Unipart provided heavy maintenance and supply chain services for over 1,050 passenger cars in the Sydney Trains metropolitan fleet, primarily at the Auburn maintenance facility located on the historic former Clyde Works site. This depot handled component change-outs, refurbishments, and logistics to ensure operational continuity for urban rail services. Since July 2024, Sydney Trains has insourced these services. In , Victoria, UGL integrates with the Newport Workshops through its stake in , utilizing the facility for maintenance and refurbishment of the metropolitan train network. Established over 130 years ago, the workshops serve as a central hub for heavy repairs and testing, supporting UGL's role in sustaining Victoria's rail operations. The Mindyarra Maintenance Centre in , , became operational in 2025 under UGL's management as part of the Regional Rail Project, focusing on the sustainment of the 117-carriage regional fleet. This purpose-built depot includes capabilities for comprehensive vehicle servicing and is integrated with UGL Regional Linx operations for the broader Country Regional Network. In , UGL is constructing the expanded Bellevue railcar maintenance plant through a with ADCO, with significant progress as of , to provide enhanced facilities for the Public Transport Authority's fleet. The depot will support heavy maintenance and operational testing for regional railcars, contributing to improved service capacity in the state. In , , the Torrens Connect joint venture between UGL and John Holland operates a dedicated depot for the maintenance of the 24-vehicle fleet, continuing infrastructure support until 2035 despite the transition of daily operations to public control in August 2025. Across these depots, UGL incorporates advanced safety technologies, such as the (CIDS), to automatically detect intrusions and mitigate collision risks during operational and activities. These systems enhance worker and , aligning with UGL's commitment to rail safety standards.

Products

Locomotives

UGL Rail specializes in the design and manufacture of heavy-duty diesel-electric locomotives tailored for 's demanding freight networks, with production rooted in the legacy of its predecessors, and Goninan & Co., which contributed to the introduction of some of 's early mainline diesel-electric locomotives in the , including the first built in in 1951. These early models, such as the 1600 HP unit produced in 1954, laid the foundation for UGL's expertise in building robust, high-traction machines compliant with standards for and safety. Over decades, UGL has delivered hundreds of locomotives for domestic operators, emphasizing reliability in harsh conditions like long-haul intermodal and bulk freight services. The NR class represents a of UGL's portfolio, with over 120 Cv40-9i units constructed between 1996 and 2002 at Broadmeadow and Bassendean facilities for Corporation, now operated by . Powered by a GE 7FDL16 16-cylinder delivering 3,000 kW (approximately 4,020 hp), these Co-Co locomotives feature advanced AC traction for superior and efficiency on standard-gauge lines, hauling heavy freight trains across interstate routes. The design, adapted from GE's Dash 9 series, includes controls for optimized performance and fuel economy. Building on the NR platform, UGL's C44ACi model has been produced for both domestic and markets since the early , with examples including 12 units for QR National, 12 for Freight Car Leasing , and additional deliveries to operators like Australian Railroad Group and . These 4,500 hp locomotives incorporate upgraded engines for reduced emissions and enhanced power-to-weight ratios, enabling them to handle steep grades and extended consists in and freight applications. For , UGL supplied 17 P class units in the for Westrail's services, demonstrating early to regional narrow-gauge needs. In electric and hybrid developments, UGL has focused on upgrading legacy diesel fleets, such as the 82 class, where recent projects installed modern electronic fuel injection systems derived from C44ACi technology to meet Tier 3 emissions standards and improve operational efficiency. Complementing new builds, UGL emphasizes refurbishment of older models like the CLF class—rebuilt variants of the original CL series from the 1970s—for continued freight service, including post-accident repairs at Broadmeadow to extend asset life. Innovations include integration of UGL's Integra platform, which embeds smart signaling and real-time monitoring into locomotives for enhanced network compatibility and predictive maintenance. Recent contracts, such as the 2021 framework for up to 123 C44 Evolution Series units for Pacific National (with initial deliveries in 2025), incorporate these features for sustainable long-haul operations, including routes to Western Australia. As of 2025, initial deliveries of the C44 Evolution Series under the 2021 Pacific National contract have commenced, with the first unit unveiled in June 2025.

Passenger Vehicles

UGL Rail has designed and manufactured a range of passenger vehicles tailored for metro, , and services, emphasizing modern features such as enhanced and lightweight materials. These vehicles support urban and regional needs, incorporating configurations like six-car sets for metro operations and double-deck designs for higher capacity in applications. Aluminum construction is a key element in many UGL designs, reducing overall weight to improve energy efficiency and performance while maintaining structural integrity. In the metro sector, UGL contributed to the project as a member of the Northwest Rapid Transit consortium, which procured and now operates the fleet of 22 six-car driverless trains equipped with (CBTC) signaling for automated operation. Delivered between 2018 and 2019, these trains feature fully accessible interiors with priority seating for mobility-impaired passengers and low-floor entry points to facilitate easy boarding. The consortium's involvement ensured integration of the vehicles with the 36 km line, supporting high-frequency services without drivers. For intercity services, UGL participates in the RailConnect NSW consortium with to design, build, and maintain the New Intercity Fleet (also known as the Mariyung or D sets) for , comprising 512 electric multiple unit cars in four-car and six-car configurations. Production began in 2017 and continues ongoing, with the double-deck trains offering wider seating, armrests, tray tables, and dedicated wheelchair spaces alongside accessible toilets to meet disability standards. These vehicles utilize aluminum bodies to minimize weight, enabling speeds up to 160 km/h while enhancing passenger comfort on routes from to the Central Coast, Blue Mountains, and South Coast. UGL has also supported and operations through builds and overhauls. Historically in , prior to 2016, UGL designed 20 Phase III vehicles (LRVs) for the in 1996, which were built in with UGL oversight, featuring low-floor designs for improved accessibility and aluminum framing for durability in urban environments. Additionally, UGL refurbished the Phase I LRVs under a 2007 contract, upgrading interiors and systems to extend service life. In , since 2020, UGL has provided operations and maintenance services for the Adelaide Glenelg fleet (the city's North-South network) as part of the Torrens Connect consortium with John Holland and . Regarding refurbishments, UGL has maintained and upgraded legacy intercity fleets in , including work on the (M sets) trains introduced in the early , ensuring compliance with current requirements through interior modifications and reliability improvements. Since the , through its facilities and predecessors like EDI Rail, UGL has produced over 1,000 passenger cars across various projects, including 160 Outer Suburban (Oscar) cars in the early and contributions to Tangara extensions, demonstrating its capacity for large-scale passenger vehicle manufacturing.

Freight Wagons and Components

UGL Rail produces a range of freight wagons tailored for bulk commodity transport, including hoppers, hoppers, and container flat wagons, designed to meet the demands of Australia's extensive rail freight network. Among its key offerings are high-capacity coal hopper wagons, such as the QHBH model built for Queensland Rail (now Aurizon), featuring 120-tonne gross loads, 30-tonne axle loads, and electronically controlled pneumatic (ECP) braking systems for efficient unloading in coal export operations. These wagons incorporate robust construction to handle heavy-duty cycles in Queensland's coal corridors, with internal designs optimized for rapid discharge and minimal residue. Grain wagons, exemplified by the XT series constructed in 2001 for Western Australia's narrow-gauge network, support agricultural freight with hopper configurations suitable for bulk grain loading and transport across regional lines. Container flat wagons, including 40 ft, 50 ft, and 60 ft variants designed by UGL for KiwiRail, facilitate intermodal shipping with tare weights ranging from 15.2 to 17.1 tonnes and compatibility for standard ISO containers. In 2025, UGL's innovative wagon delivery projects, including flat-pack assemblies, earned nominations in the Australasian Railway Association's Rail Industry Awards, highlighting advancements in efficient freight solutions. UGL Rail also manufactures essential components such as s, couplers, and braking systems, often customized for the sector to enhance performance in harsh environments. Through joint ventures like the one with , UGL supplies frames, platforms, and undercarriage components engineered for high-load and compatibility with Australian track gauges. For applications, such as BHP's ore operations, UGL has developed modular flat s using a flat-pack assembly process that allows for local construction at its Bassendean facility, enabling quick reconfiguration for specific payload requirements like 30-tonne axle loads. Over its history, UGL has delivered more than 11,000 wagons across 40 types, with recent production emphasizing resilience for Australian conditions, including dust-resistant seals and suited to arid and coastal freight routes. Annual output supports major contracts, such as the assembly of 140 wagons for over four years, focusing on scalable to meet sector demands. efforts incorporate material selections that reduce overall wagon weight, contributing to lower consumption in freight , though specific reductions vary by design. These components integrate seamlessly with UGL's offerings to form complete heavy-haul consists for bulk .

Services

Maintenance and Refurbishment

UGL Rail provides comprehensive maintenance and refurbishment services to sustain rail fleets, focusing on enhancing reliability, safety, and operational efficiency across Australia's rail networks. These services encompass heavy overhauls, routine inspections, and the integration of advanced technologies to extend asset life and minimize disruptions. Through joint ventures and direct contracts, UGL Rail supports major operators by delivering end-to-end solutions that include component replacements, upgrades, and predictive strategies to optimize fleet performance. Overhaul programs form a core component of UGL Rail's offerings, involving full refurbishments that extend the operational life of by over 15 years in some cases. For instance, UGL completed a fleet refresh for 446 Tangara passenger cars in Sydney's metropolitan network, incorporating state-of-the-art passenger amenities and structural upgrades to improve comfort and durability. More recently, in partnership with Corporation, UGL is executing a life-extension program for five Dash 9 locomotives owned by Fortescue Metals Group in , which includes comprehensive work on engines, bogies, traction motors, wheelsets, cabs, and body structures to restore full functionality. These programs emphasize meticulous disassembly, repair, and reassembly to meet stringent safety and performance standards. Routine maintenance services by UGL Rail involve scheduled inspections, component replacements, and preventive measures to ensure ongoing fleet reliability. These activities include regular servicing of over 1,050 passenger cars in Sydney's metropolitan fleet under the UGL , covering heavy maintenance tasks such as wheelset overhauls and electrical system checks. To reduce downtime, UGL Rail employs through its Integra platform, which monitors train statuses in real-time, anticipates potential failures, and enables proactive scheduling of interventions, thereby minimizing unplanned outages and enhancing overall network efficiency. Key contracts underscore UGL Rail's expertise in fleet sustainment. In 2019, UGL secured a A$630 million five-year extension with , effective from July 1, to provide and logistics services for a significant portion of the metropolitan passenger rail fleet, building on prior commitments for heavy and support. Additionally, through the Torrens Connect with John Holland, UGL Rail handles the upkeep of Adelaide's Glenelg fleet and associated , with responsibilities extending until 2035 following the transfer of operations to public control in 2025. These agreements highlight UGL Rail's role in delivering consistent, high-volume services across diverse rail assets. Technological innovations enhance the safety and precision of UGL Rail's maintenance processes. The company has developed the Corridor (CIDS), an Australian-first solution deployed on the , which uses advanced sensors to detect unauthorized intrusions along rail corridors, thereby improving safety during maintenance and operational activities. While robotic welding is increasingly adopted in rail refurbishments industry-wide for precision repairs, UGL Rail integrates similar in its workshops to support efficient component refurbishment. These tools contribute to safer working environments and higher-quality outcomes in sustainment projects.

Design and Engineering Solutions

UGL Rail offers bespoke design services in signaling integration, including components compatible with (ETCS) Level 2 for automatic train protection and trackside applications. These solutions enable enhanced safety and operational efficiency in rail networks through custom-developed systems like SigView, an Australian-designed train control platform that supports evolving rail requirements. Feasibility studies for rail upgrades form a core part of UGL's consultancy, assessing needs to support modernization projects. In consulting roles, UGL provides for major initiatives, such as the Gippsland Line Upgrade in Victoria, where it oversaw track duplication, signaling enhancements, and level crossing improvements to enable more frequent services. This involves coordinating multidisciplinary teams to deliver upgrades on time and within budget, ensuring seamless integration of new technologies into existing networks. UGL advances smart railway enhancements through its Integra platform, an integrated and (OMCS) designed for real-time monitoring and optimization of rail networks. Integra facilitates secure of systems, incorporating features like electrical and route to improve reliability and in rail operations. Built on over 30 years of expertise, it supports broader applications in smart mobility by enabling precise data-driven decisions. Notable engineering collaborations include the and of a 5MW Traction Feeder Substation at the Bellevue Depot in , completed in 2025 to power new maintenance facilities for the Public Transport Authority. This project exemplifies UGL's expertise in for rail infrastructure, integrating high-capacity power solutions to support fleet operations. UGL also applies specialized in areas such as power systems for projects in , contributing to efficient and reliable .

Major Projects

New South Wales

UGL Rail has played a significant role in ' rail infrastructure through its involvement in the Northwest Rapid Transit consortium, which designed, constructed, financed, and operates the line. This 36 km automated system, opened in May 2019, includes a fleet of 22 driverless trains manufactured by , supporting turn-up-and-go services from Tallawong to Chatswood. UGL contributed to the project's systems integration and delivery as part of the with , John Holland, CPB Contractors, and others. For the project, UGL, in with CPB Contractors as Systems Connect, secured a A$1.376 billion contract in 2018 to deliver line-wide works, including signaling, communications, and safety systems across the 30 km extension from Chatswood to via CBD. This ongoing effort incorporates 2025 innovations such as Australian-first safety features for driverless operations, enhancing network reliability and capacity for up to 40,000 passengers per hour. These contributions support the full line's operational readiness, with the Sydenham to section scheduled for opening in the second half of 2026, following high-speed testing that commenced in November 2025. The New Intercity Fleet project represents one of UGL's largest commitments in NSW, with UGL as a key member of the RailConnect NSW consortium alongside Hyundai Rotem Company and Mitsubishi Electric Australia. Awarded an initial A$2.3 billion contract in 2016 for 512 double-deck electric multiple unit carriages, later expanded to 610 carriages under a A$2.4 billion agreement, the consortium is designing, building, and maintaining the fleet forming 65 eight-car sets (with additional sets) for Sydney's intercity network, serving routes to the Central Coast, Newcastle, Blue Mountains, and South Coast. Deliveries commenced in 2023 and are scheduled through 2026, replacing aging V-sets with modern trains featuring improved accessibility, Wi-Fi, and higher capacity. UGL's share includes 15 years of maintenance and asset management services valued at approximately A$570 million. In regional NSW, UGL Regional Linx holds a 10-year operations and maintenance contract for the Country Regional Network (CRN), commencing January 2022 and extending to 2032, covering 2,386 km of track connecting regional areas to and interstate lines. Valued at A$1.5 billion, the contract ensures safe freight and passenger movements, including infrastructure upgrades and vegetation management. Complementing this, the Mindyarra Maintenance Centre in , completed in mid-2024, is operated by UGL Contractors as part of the for the Regional Rail Project, servicing 29 new regional trains with facilities for heavy maintenance and stabling. Additionally, UGL provides heavy maintenance and supply chain services for over 1,050 passenger cars in 's metropolitan fleet, including parts supply and refurbishments at Auburn. In 2025, UGL Regional Linx partnered with on the A$13 million Wumbulgal rail siding project near Parkes, constructing a 1.5 km to boost freight efficiency for grain and other commodities, with works completed in November 2025. These NSW projects have delivered measurable outcomes, including over 99% on-time performance for the line, contributing to high customer satisfaction and reduced travel times. Collectively, initiatives like the CRN contract, Mindyarra Centre construction, and intercity fleet maintenance have created more than 500 jobs, encompassing construction roles, operational positions, and apprenticeships across regional and metropolitan areas.

Victoria

UGL Rail holds a 20% stake in , a formed in 2009 with (60%) and (20%), responsible for operating and maintaining Melbourne's metropolitan rail network. This includes servicing 15 lines, over 200 stations, more than 900 km of track, and a fleet of 269 six-carriage trains, transporting approximately 450,000 passengers daily. Through its role in the consortium, UGL Rail provides specialized services in design, engineering, manufacture, and refurbishment, contributing to the maintenance and reliability of the fleet, including the 65 High Capacity Metro Trains introduced during the to boost capacity on key lines like Cranbourne, Pakenham, and Sunbury. These efforts have supported fleet expansions and upgrades, with UGL's expertise aiding partial refurbishments and ongoing upkeep to meet growing demand. UGL's Spotswood maintenance centre in Melbourne's western suburbs further bolsters these operations, handling heavy maintenance for locomotives and , including support for metropolitan services and integration with legacy projects like the Regional Rail Link, where UGL formed part of a 2011 awarded a A$1.6 billion to construct segments of the 47.5 km line separating regional and suburban traffic. A key recent contribution is UGL's involvement in the 2025 Gippsland Line Upgrade as part of the VicConnect consortium, delivering track duplications between and Sale, extensions to the Morwell crossing loop, signaling and upgrades, and new platforms at key regional stations such as Moe and , enabling more than 80 additional weekly services and enhancing regional connectivity. These initiatives have yielded measurable impacts, including a reduction in train service delays caused by infrastructure failures through improved , alongside recognition via awards for fleet reliability and system modernizations that enhance .

Western Australia and South Australia

In , UGL Rail has undertaken significant and projects to support the state's expanding and freight networks. In April 2024, UGL, in with ADCO Constructions, was awarded a valued at over A$110 million by the Public Transport Authority to construct new railcar facilities at the existing Bellevue Railcar and Facility in Perth. This expansion includes specialized workshops, storage areas, and administrative buildings to enhance capacity for servicing the growing fleet of railcars, contributing to the reliability of METRONET's urban rail services. Complementing this, UGL completed the construction of a 5 MW Traction Feeder Substation at Bellevue in September 2025, providing essential power for the new operations and supporting efforts across the network. UGL's Bassendean facility in Perth has been a key hub for manufacturing and overhauling rail components tailored to Western Australia's mining sector. In 2022, the site assembled up to 140 'flat pack' iron ore railcars for BHP under an innovative local manufacturing initiative, boosting domestic production capabilities and reducing reliance on imported rolling stock for Pilbara iron ore transport. The facility also handles life extension programs for heavy-haul locomotives, such as the ongoing refurbishment of five Dash 9 units for Fortescue Metals Group in partnership with Wabtec Corporation, ensuring extended service life for critical mining freight operations in the Pilbara region. These efforts at Bassendean emphasize modular component design, enabling efficient sharing of parts across state-based rail projects to optimize supply chains for resource transport. In , UGL Rail's involvement centers on urban maintenance through the Torrens Connect with John Holland, which assumed responsibility for operations and upkeep of Adelaide's North-South Corridor network in July 2020 under an initial 10-year agreement. This includes the iconic , where Torrens Connect managed a fleet of over 24 vehicles and associated infrastructure until operations transitioned back to state control in August 2025, with maintenance responsibilities extending to 2035. The partnership has focused on enhancing service reliability and safety, integrating tram maintenance with broader bus operations across more than 15 routes to serve metropolitan Adelaide's needs. UGL has also supplied freight wagons to support South Australia's logistics, including components for intermodal and on regional lines, aligning with efforts to strengthen cross-state freight connectivity. These projects in both states leverage UGL's expertise in shared solutions, such as standardized underframes and diagnostic systems, to facilitate seamless integration between Western Australia's resource-heavy rail corridors and South Australia's urban and export-focused networks.

Recent Developments

Contract Extensions and New Builds

In the early 2020s, UGL Rail secured significant contract extensions that solidified its role in maintaining key rail networks in . The UGL Unipart , a 70:30 partnership between UGL and Rail, was awarded a five-year extension in July 2019 for heavy maintenance and supply chain services to , covering more than 1,050 passenger vehicles and generating approximately A$630 million in revenue. This extension, effective from July 1, 2019, built on prior agreements and ensured continued support for Sydney's metropolitan fleet until 2024. Similarly, in February 2021, UGL was selected for a 10-year contract to operate and maintain the Country Regional Network (CRN) in regional and rural , valued at over A$1.5 billion and commencing in January 2022, encompassing 2,386 kilometers of operational passenger and freight lines. Through its UGL Regional Linx entity, UGL manages network operations, track maintenance, and upgrades under this agreement, which extends through 2032. Turning to new builds, UGL Rail has pursued infrastructure projects enhancing freight and passenger capacity. In July 2025, UGL Regional Linx partnered with on a A$13 million contract from to construct a 1,500-meter multi-user rail siding at Wumbulgal, between Griffith and Leeton, aimed at improving reliability for grain and freight by allowing longer to or pass without blocking the main line. Construction began in July 2025 and is scheduled for completion by November 2025. In Victoria, as part of the VicConnect consortium, UGL contributed to the Gippsland Line Upgrade, which concluded in August 2025 and enables over 80 additional weekly services starting September 14, 2025, including track duplications, crossing loop extensions, and new platforms at key stations like Morwell and to support more frequent off-peak between and . Domestically, UGL Rail has scaled up wagon production, contributing to the delivery of over 450 new flat wagons to in by the end of 2025 as part of a NZ$291 million order in collaboration with PT Inka, exceeding 100 units and enhancing intermodal freight capacity across the Tasman. Additionally, the Mindyarra Maintenance Centre in , , was completed in late 2025 and is now operated by UGL for 24/7 maintenance of the new regional fleet under the Regional Rail Project, employing local workers. In November 2025, agreed to sell UGL, including its rail division, to Japan's Corporation for approximately A$950 million (equivalent to 560 million euros), advised by . The transaction, valued at over A$1 billion with an expected EBIT of A$100 million, ensures no disruptions to ongoing contracts such as the CRN and services, underscoring UGL's strategic positioning in Australia's rail sector.

Innovations and Industry Recognition

In the 2020s, UGL Rail has advanced rail safety through the development of the Corridor Intrusion Detection System (CIDS) and Obstacle Detection System (ODS), marking an Australian first in automated perimeter intrusion detection for metro networks. These systems, developed for and being installed on the Sydney Metro, use advanced sensors to detect unauthorized intrusions and obstacles along rail corridors, enhancing operational security and preventing potential collisions without human intervention. UGL's innovations in this area were showcased at the CORE 2025 conference, where they sparked discussions on global rail safety improvements. UGL Rail's Integra platform represents a key contribution to smart railway systems, providing an integrated digital solution for central operations control, mechanical and electrical plant monitoring, train management, and signaling. Launched prominently in 2025, Integra enables precise monitoring and optimization of complex rail networks, supporting sustainable mobility by improving energy efficiency and reducing downtime through . This technology has been applied in projects like modernizing systems for planned rail replacements, contributing to enhanced reliability in passenger operations. The company's involvement in driverless metro operations further demonstrates forward-looking innovation, particularly through the project, Australia's first fully automated driverless rail line spanning 36 km. This initiative set benchmarks in efficiency and safety, incorporating state-of-the-art automation that supports higher service frequencies and reduced operational costs. Additionally, UGL Rail's collaboration with on the Series locomotives, unveiled in 2025, advances sustainable freight by introducing Australia's greenest diesel-electric fleet, featuring lower emissions and improved fuel efficiency for long-haul transport. UGL Rail received significant industry recognition in 2025, including 11 finalist nominations in the Australasian Railway Association's (ARA) Rail Industry Awards across categories such as safety innovations, passenger operations, and workplace culture. UGL won the Excellence Award for the G.R.E.A.T. initiative—standing for Growth, Relationships, Energy, Authenticity, and Trust—for fostering positive workplace culture in Western Australia's rail teams, and was a finalist for Rail Innovation of the Year with CIDS and for Rail Freight Excellence with the Wagon Replacement Program . These recognitions underscore UGL Rail's leadership in Australian rail advancements, with winners announced at the 2025 ceremony in .

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