Protecting Critical Infrastructure: FRP Switchgear Supports in the Metro Tunnel

In major transport projects like Melbourne’s Metro Tunnel, every component plays a role in ensuring safety and operational reliability. Electrical switchgear systems are particularly critical and when water ingress occurs, it can lead to costly tunnel shutdowns and serious safety hazards.

To address these risks, Cross Yarra Partnership engaged Terra Firma Industries to deliver a non-conductive, corrosion-resistant FRP support system that would elevate and protect vital electrical equipment.

The Challenge: Water Ingress Threatening Electrical Safety

The switchgear units within the tunnel were exposed to water ingress, creating both operational interruptions and electrical hazards. The project required a durable, non-conductive solution capable of elevating the equipment above floor level, one that could perform reliably in a high-moisture, confined environment.

Traditional steel or aluminium frames were ruled out due to their conductivity, weight, and corrosion risk.

The Solution: FRP Switchgear Supports Built for Reliability

Terra Firma supplied TerraGrate FRP Pultruded Supports (RAL 7015) — a lightweight structural system engineered for electrical safety in tunnels and other high-risk environments.

The FRP support system provided:

• Non-conductive protection for switchgear equipment

• Corrosion-resistant, water-tolerant materials to withstand tunnel conditions

• Lightweight handling for faster, safer installation

• Long-term performance with minimal maintenance

The result: a robust FRP switchgear support system that prevents future water-related shutdowns and improves operational reliability for the Metro Tunnel network.

Why FRP Outperforms Traditional Materials

FRP (Fibre Reinforced Plastic) offers clear advantages for electrical and tunnel infrastructure:

• Non-conductive: Eliminates electrical risk to personnel and assets

• Corrosion-resistant: Withstands moisture and chemical exposure

• Lightweight yet strong: Reduces installation time and manual handling strain

• Low maintenance: Long-term durability with minimal intervention

For large-scale infrastructure projects, these benefits make FRP the material of choice for non-conductive supports and corrosion-resistant systems.

Partnering for Safer Infrastructure

With decades of experience in composite infrastructure materials, Terra Firma Industries continues to support Australia’s most complex projects, helping contractors and government partners reduce risk, enhance safety, and extend asset life.

Whether it’s switchgear supports in the Metro Tunnel or FRP grating solutions for other electrical or transport applications, Terra Firma Industries provides the reliability and expertise that critical infrastructure demands.

Looking for compliant, low-maintenance solutions for electrical safety in tunnels or transport infrastructure? Contact our team to discuss your next project.