The Australian rail industry has taken another step forward in improving safety with the release of the updated AS 7520.1 – Rolling Stock Body Structural Requirements – Locomotive.
This revision, shaped by lessons from the tragic derailment of the XPT passenger train at Wallan, Victoria, in February 2020, aims to enhance the protection of train crews and improve the crashworthiness of locomotives in the event of serious incidents.
Learning from Wallan
The Wallan derailment was a sobering reminder of the risks faced by train crews and passengers if a train leaves the tracks and overturns. The two crew members in the leading powercar locomotive lost their lives, while other onboard crew and passengers in the carriages were injured.
The XPT train was designed in the 1970s to the standards of the time, rather than contemporary standards.
The Australian Transport Safety Bureau (ATSB) investigation that was completed in August 2023 found that the existing AS 7520.1 standard did not include structural requirements for cab doors, or other performance-based requirements, that addressed the protection of train crew in the case of vehicle overturn. In response, the Rail Industry Safety and Standards Board (RISSB) committed to a targeted review of the standard to close these gaps. The outcome further strengthens requirements for the design and construction of locomotive bodies.
Stronger requirements
The revised standard introduces several important enhancements aimed at protecting crews during derailments, collisions, or rollovers.
“This important Standard has been updated to improve crashworthiness in the event of an incident,” said Bruce Wooldridge, RISSB’s Standard Development Manager.
“The Development Group worked hard on debris ingress areas such as cab-mounted doors and windows, which were key factors in the Wallan derailment.”
Along with improved glazing requirements based on aerodynamic load and alignment of penetration resistance standards with current industry best practice adherence, these changes focus on maintaining a “safety cell” around the crew area, providing drivers far greater protection from harm in serious incidents.
The benefits of the standard
The central aim of AS 7520.1 remains the same: to prescribe the minimum structural integrity of locomotive bodies so they perform safely under both normal and extreme operating conditions.
The updated version significantly strengthens the standard’s ability to manage critical issues such as injury or death of train crews, damage to infrastructure and rolling stock, and derailments and collision impacts.
For rail operators and manufacturers, this means future locomotive and power car designs should incorporate these enhanced safety measures from the outset, creating a safer operating environment across the network.
A systematic approach
Adopting AS 7520.1 requires more than simply noting the changes – it calls for a structured review of existing internal standards and rolling stock designs. RISSB recommends a systematic approach:
Compare AS 7520.1 with internal standards to identify commonalities and differences.
Apply organisational change management processes to update requirements where alignment is possible.
Assess whether AS 7520.1 delivers superior safety or interoperability outcomes compared with current practices.
Update internal standards accordingly, while documenting any justified derogations or deviations.
By embedding AS 7520.1 into internal frameworks, organisations will improve safety and help harmonise practices across the industry.
A safer future for rail
The revised AS 7520.1 is more than just a technical update – it represents the rail industry’s ongoing commitment to learning from past tragedies and ensuring those lessons translate into safer operations.
By specifying new requirements for crew cabs, crashworthiness in rollover events, and stricter glazing and door requirements, the standard addresses vulnerabilities identified by the ATSB at Wallan.
Rail is one of the safest modes of transport, but there is always room to improve. With AS 7520.1 in place, the Australian rail industry is better equipped to manage risks, protect lives, and maintain public confidence in the safety of train travel.
Keith McMahon, Assistant National Secretary (Locomotive Division) from the Rail, Tram and Bus Union Australia (RBTU) who had also participated in the Development Group, said: “The work RISSB and the Development Group members has done on AS 7520.1 will save lives in the event of a major incident.”
