Welding bay hazard containment for QR rollingstock depot

PROJECT:

Sonic Acoustic Welding Bay

INDUSTRY TYPE:

Rail infrastructure and rollingstock maintenance

CLIENT:

Queensland Rail

LOCATION:

Portsmith Depot, Cairns QLD

Initial project requirements:

To safely contain welding sparks and associated hazards within its Portsmith rollingstock maintenance depot, Queensland Rail required a dedicated hot works enclosure. The finished project would also need to ensure efficient workshop access and workflow inside the busy Cairns rail maintenance environment.

QR determined that the welding bay would need to measure 6750 mm x 5000 mm, with a structure height of 3000 mm. The design brief specified:

Two fixed side walls manufactured from solid acoustic welding panelling
Open ends fitted with curtain systems to allow for operational access
Curtains mounted on rails fixed to the two solid side walls
No internal posts that could interfere with welding activity
Compliance with relevant drafting and documentation standards, and
Structural considerations for safe maintenance access to the roof.

Queensland Rail also required CAD drafting services, as-built drawings for approval and handover, and confirmation of delivery and installation timelines. Importantly, they began by requesting a site consultation in order to confirm accurate measurements, assess site access, and determine the most suitable structural configuration.

The overarching priority was to support Health, Safety, Productivity within an active rollingstock maintenance environment.

Flexshield solution:

Flexshield Group designed and delivered a purpose-built Sonic acoustic welding bay tailored to the operational needs of the rollingstock depot.

The enclosure incorporated:

Solid 50 mm thick acoustic welding panels to both 6750 mm side walls
Roof panelling to assist in containing sparks and hot works activity within the defined area
A pre-coated Dulux Grey Nurse finish suited to industrial workshop conditions
Galvanised capping channels for durability and long service life

The enclosure’s two open ends were fitted with Weldflex^TMstrip curtains which were:

4530 mm wide x 3000 mm high
Supplied as a four-panel slider system
Mounted on rails fixed directly to the two solid acoustic side walls

The solid acoustic welding panels provide both physical spark containment and sound attenuation, helping reduce noise transfer into surrounding workshop areas while maintaining a robust industrial barrier. And the sliding Weldflex^TM curtain systems allow practical access without compromising containment when closed.

Designed around the demands of heavy industrial use, the structural framework utilised galvanised steel support posts, pre-coated panels, and PFC head rails, engineered to eliminate internal posts within the welding bay. This preserved clear internal working space for rollingstock maintenance tasks and reduced obstructions around active hot works.

All required fixings were supplied as part of the Flexshield package. The project complied with AS3957 2014 CAD drafting requirements, with a full set of as-built drawings provided for approval and handover.

A Flexshield technician conducted a detailed site consultation to confirm accurate measurements, check access constraints, and provide professional advice on structural upgrades that would allow safe roof access for maintenance purposes.

Results achieved:

Queensland Rail received a practical, engineered solution designed to perform safely and reliably within their live rail maintenance environment. The completed hot works enclosure now provides the Portsmith rollingstock depot with a clearly defined, purpose-built welding zone.

The enclosure positions hot works activity out of the way of general maintenance traffic, supporting safer workshop operations. Welding sparks and associated hazards are now contained within a controlled area, reducing risk to adjacent personnel, equipment, and infrastructure.

While the project’s primary objective was spark containment and safe segregation of hot works, the enclosed structure also provides improved environmental control within the designated area.

The Portsmith sonic welding bay now provides Queensland Rail with a durable, purpose-built hot works enclosure that supports safer operations and efficient workshop workflow. The outcome is a compliant, engineered acoustic welding bay aligned with Health, Safety, Productivity objectives across the Portsmith facility.

For a detailed assessment and consultation, call Flexshield on 1300 799 969 or contact us online.