Karabiner completed design and installation works for six overhead material handling rail systems at Powerhouse Museum Parramatta. With ongoing works to supply 2 BMU systems for this iNSW project, Karabiner were engaged by the head contractor, Lendlease, to complete additional works supplying rails capable of a 1 tonne capacity for an internal presentation space.
Client Challenges
Before Karabiner’s involvement, the client identified several risks and constraints that existing trade packages could not resolve. The project required a material-handling system capable of supporting significantly higher loads across long-span structural steel fixing points, all while remaining compact and visually unobtrusive within the soffit space. Other trades on the project had already been engaged to supply lighter-duty rails, but these systems were not suited to the client’s operational requirements. Karabiner’s advanced material-handling expertise and proven capability in designing for complex access, construction, and logistical conditions made their involvement critical, ensuring the client received a robust, high-capacity solution integrated safely and seamlessly into the constrained overhead environment.
Our Solution
Karabiner implemented a fully integrated Bomac rail system, working closely with the rail supplier designing a strongback stiffening method to support heavy loads across large spans between fixing points while remaining compact and discreet. The team coordinated closely with the head contractor and steel contractor to connect the rail to structural steel and meet the tight tolerances required for accurate installation. In addition, Karabiner developed a custom end-stop design tailored to provide the discreet visual finish desired while also enabling the specific trolley access and functionality required for the client’s operations. This solution combined careful planning, structural coordination, and specialised innovation to deliver a reliable, high-capacity overhead handling system.
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Execution & Methodology
Karabiner supplied detailed installation methodology and SWMS, coordinating with the Lendlease Safety team to ensure the complex installation of the rail was done in a safe and efficient manner.
Key tasks include:
· Cutting and preassembly of material at slab level
· Lifting the assembled lengths of rail to the steelwork above
· Bolting the rail to steel dropper, levelling the rail to account for tolerance of the steel
· Torquing bolts as per the installation requirements
· Adding rail joiners as necessary
The install works required 2 scissor lifts with material strapping mechanisms to lift and install the rails to the ceiling 11 meters above the slab below. Karabiner coordinated closely with Lendlease to sequence the works around other trades working in the area.
Key Outcomes
· Material handling rail was installed without program delays and fully certified
· Zero incidents recorded throughout the installation
· The discreet design conforms with the visual intent of the space
· A fit for purpose and compliant system can now allow for heavy duty material handling for the long-term future use of the Museum