Project Name: Keolis Downer Northern Beaches – Bus Electrification Gantry
Project Overview: Design, fabricate, and install a modular bus charging gantry with access systems and stormwater integration.
Project Location: Brookvale, Sydney, NSW
Type of Shed/Solution: Industrial Facility
Project Overview
Asset Building Systems proudly partnered with Keolis Downer Northern Beaches to deliver a tailored Bus Electrification Gantry project at their live depot in Brookvale, Sydney. With clean energy infrastructure becoming essential in public transport, this gantry supports the next generation of electric buses while improving workplace safety and operational flow.
Designed for durability and ease of access, the scope included galvanised structural steel fabrication, personnel access walkways, handrails, W-barrier (guard rail) protection, cladding, and stormwater management.
Project Scope and Objectives
The project’s primary objective was to construct a robust and safe Bus Electrification Gantry solution that allowed charging infrastructure and personnel access to coexist in a tight operational depot.
Scope included:
• In-house fabrication of galvanised steel gantry modules
• Preassembly and partial cladding in the Asset workshop
• In-house trucking to manage tight delivery windows
• Onsite installation of gantry modules with minimal depot disruption
• Access grating and compliant handrails
• Walkway protection using W-barriers
• Stormwater integration into gantry roofing design
• Non-destructive testing (NDT) of steel for quality assurance
Design and Preassembly Strategy
Asset’s design phase focused on reducing on-site risk and time through modular construction. The gantry was broken down into smaller components that were:
• Fabricated and preassembled in the controlled environment of Asset’s workshop
• Cladded in advance to minimise the need for working at height
• Transported using Asset’s in-house fleet, reducing dependency on third-party logistics and ensuring precision delivery during narrow time slot
This proactive approach was critical as the site remained operational with over 220 buses navigating the depot daily.
Onsite Installation Process
With modules prepped off-site, the installation phase was swift and controlled:
• Gantry components were offloaded using site-specific equipment
• The Asset team installed access grating, W-barriers, and safety handrails
• Covered walkway features were completed to protect both drivers and maintenance crews
• All structural connections were finalised with minimal traffic disruption
• Stormwater management systems were integrated into the gantry cladding
Project Challenges and Solutions
Tight Site Conditions:
The depot’s live operation presented limited space and movement windows. Asset mitigated this by:
• Pre-building gantry sections off-site
• Delivering during off-peak hours using internal transport
• Carefully sequencing installation around bus movements
Safety and Quality Standards:
To meet stringent clean energy infrastructure requirements, Asset conducted:
• Detailed planning to reduce working at heights
• Full NDT (Non-Destructive Testing) on steel components before dispatch
• Strict compliance with workplace access and safety standards
Client Collaboration and Adaptability
Throughout the project, Asset maintained close communication with the Keolis Downer team to accommodate real-time operational demands. The ability to pivot fabrication schedules, adjust delivery timelines, and offer in-house solutions made the process seamless for the client.
Completion and Outcomes
The Bus Electrification Gantry was completed on time and to spec, delivering:
• Safe and compliant elevated access for equipment and staff
• Seamless integration with charging infrastructure
• Minimal interruption to ongoing bus operations
• A weather-protected environment for daily personnel movement
• Long-term performance and easy maintenance
Benefits Secured
• Reduced on-site labour and installation time
• Improved safety through modular off-site fabrication
• Covered walkway improves driver and staff experience
• Minimal depot disruption during installation
• High-performance infrastructure supporting clean energy rollout
Future Opportunities and Maintenance
With increasing demand for sustainable public transport solutions, this project places Asset Building Systems at the forefront of bus depot electrification infrastructure. Ongoing support and maintenance insights have already been shared with the Keolis Downer team, ensuring long-term gantry performance.
Final Thoughts
The Keolis Downer Northern Beaches Bus Electrification Gantry project is a testament to Asset Building Systems’ capability in delivering safe, smart, and sustainable industrial infrastructure. Through a focus on modular design, in-house expertise, and client collaboration, the team successfully installed a critical piece of clean energy infrastructure in a high-traffic, space-limited depot.
For your next industrial or transport infrastructure project, trust Asset Building Systems to build strong for the future of transport.
