Revised design of signal poles used at active level crossings of cane railways

Wilmar Sugar recently initiated an engineering review process that led to a revised design of the poles used at their active level crossings signals. This review was instigated after a few recent premature failures of poles at their maintenance hinge. The review?s objectives were to understand the failure mechanism of these observed failures as well as use the opportunity to obtain an independent mechanical and structural review of Wilmar?s standard documented pole design, a legacy design that had been modified over time. These targeted objectives of the review were achieved. The review highlighted a number of non-compliance issues with the current standards and resultantly the design was revisited. By engaging with maintainers during the redesign process, opportunities to improve maintainer safety, productivity and roadway availability were identified and considered within the new design developed. The key features of the re-designed pole include a change in the construction material, the relocation of the maintenance hinge to a more optimized location, and the addition of facilities for the use of a chain block as a mechanical aid to assist maintainers with lifting and lowering the pole safely. The new pole design is ready for prototyping and validation. Once the final construction details have been validated with the prototype, the new design will be installed at two of Proserpine Sugar Mill?s level crossings along two main highways. This will see the realization of the achieved improvements at two high-risk active level crossings from the 2024 sugarcane processing season onwards.