The North East Link will reshape how Melbourne moves, linking the city’s north and east in ways planners have envisioned for decades. But while commuters look forward to faster journeys, those building the project face a very different challenge: staying safe in some of the most hazardous conditions in construction.
Among those leading the effort is Steve Lonsdale, Lift Supervisor on the Spark North East Link central package, where cut-and-cover tunnels are being constructed. Steve and his team are overseeing heavy lifting operations in some of the most high-risk conditions on the project. For them, new safety technology has already changed the way they work.
To support the tunnelling operation, three brand new Franna MAC25 cranes were purchased. Each was fitted with Protective Engineering Safety’s GoUpSafely system and Protective Shield. These two innovations have been designed to prevent fatal accidents on worksites.
“On any site, the danger is always there – an operator could be telescoping the boom and if you take your eyes off for a second, you risk coming into contact with live power lines,” Steve said. “These systems give us a secondary layer of protection that’s engineered to stop that from happening.”
The GoUpSafely system uses four magnetic sensors mounted near the boom tip to detect overhead power lines carrying 1000 volts or more. The wireless system feeds into an in-cab display, warning operators in three stages: no alert, orange for caution, and red for danger.
This is the world’s first dual secondary guarding system of its kind, according to Protective Engineering Safety. “For years, the industry has been asking how can we stop cranes from coming in contact with power lines. Now we’ve got a real, engineered solution,” Steve said.
The latest version of GUS V3 also links to a mobile app, allowing supervisors to adjust sensitivity based on conditions. “When we’re working out in the open, I can reduce the sensitivity knowing there’s no chance of coming in contact with a power line. But underground, where we’ve got 66 kilovolt (kV) power cables running through the tunnels, I can turn the sensitivity right up,” Steve said. “It gives us that flexibility to match the system to the environment.”
Even shielded power cables can trigger alerts, keeping operators on their toes. “The feedback from the crew has been positive. They know the system is sensitive, but it keeps them alert – which is exactly what we want,” Steve said.
Protective Shield: Watching the overhead
The Protective Shield sensor works in tandem with GUS. Mounted at the boom tip, it constantly points upward, scanning for physical obstacles above the crane.
“In a tunnel environment, you’ve got low clearances and overhead hazards that can damage equipment or injure workers. The Shield sensor detects those risks and sends an alarm straight to the operator,” Steve said. The combination of GUS and Protective Shield creates a 360-degree safety net – covering electrical and physical hazards that are among the biggest causes of crane-related incidents.
Backed by strong support
Both systems were installed on the Frannas before delivery, with Terex and Protective Engineering Safety working together to integrate them seamlessly. “The handover was really thorough. We were given all the information we needed, and our team felt confident straight away,” Steve said.
Protective Engineering Safety, led by Karl Rosewarne and Jason Jordan, has built a reputation for being highly responsive to contractors’ needs. That support, Steve said, has been a major part of the smooth rollout on site.
The GUS V3 system represents the next step in overhead powerline detection, providing wireless communication, increased sensitivity, and integration with operator training frameworks. Similarly, Protective Shield is marketed as an “early warning system against collision”, designed to complement physical barriers and spotters.
For Steve, the combination of these technologies is not just about compliance – it’s about saving lives. “Human error will always be part of construction. You can have spotters, barriers, and procedures, but there’s always that small percentage of risk. These systems close the gap. They make sure a moment’s lapse doesn’t turn into a tragedy,” he said.
Looking ahead
Technologies like GoUpSafely and Protective Shield are already lifting the standard for crane operations, but their impact reaches beyond construction sites. Protective Engineered Safety extends its expertise into the rail sector, where the ability to reliably detect both alternating current (AC) and direct current (DC) high-voltage lines could transform safety for operators of rail, tram and light rail networks.
The company is developing a world-first AC/DC GoUpSafely system, aimed at solving one of rail’s most persistent safety challenges: reliable detection of both AC and DC high-voltage lines.
The experience with similar sensors on the North East Link project shows that a wider shift is happening across the industry. Safety is no longer about checklists, it’s about engineered solutions that remove risk at its source.
“These machines have been set up with the best of the best. It’s the direction the industry is heading, and it’s the only way we’ll keep improving safety,” Steve said. With hundreds of workers underground and heavy equipment operating in confined spaces, innovations like these could mean the difference between another day on the job and a life lost.