Case Study: M4 Downer Transurban Workzone Digitisation Trial

 

As infrastructure projects continue to grow in scale and complexity, workzone safety needs to remain top priority for project managers, road operators and contractors. To address these challenges, Downer | Transurban conducted a trial of Workzone Digitisation on the M4 Motorway on February 13 this year. 

Workzone Digitisation integrates smart technologies to create safer and more efficient roadwork environments. By using real-time data, automated alerts, and remote monitoring, digital systems can detect potential hazards, track compliance, and provide instant notifications to traffic management teams. 

Compared to traditional manual inspections, digitised workzones offer greater accuracy and responsiveness when it truly matters. Digital sensors and signage tracking ensure that regulatory measures remain in place throughout the work period, while automated alerts provide early warnings of potential safety risks. Additionally, the use of digital signage reduces the need for routine site inspections, minimising road worker exposure to live traffic. 

SAFETY INSIGHTS

Incursion Alarms 
These alarms immediately notify traffic controllers and workers in case of unauthorised entry or threatening situations within the work zone, enabling rapid responses. 

This trial recorded multiple incursion alarms, providing key data on potential worksite breaches: 

  • 22:59 PM: A truck attempting to avoid overhanging branches struck four cones (~ 6m from workers). 

  • 23:41 PM: A tray truck (MOP vehicle) hit cones while travelling in the shoulder. 

  • 01:51 AM:  MOP vehicle struck cones at the merge taper (~ 65m from workers). 

  • ·02:21 AM: A MOP vehicle clipped a cone near the first patch (~ 3m from workers) .

The majority of cone strikes occurred in areas with restricted space due to encroaching vegetation. While many incidents were controlled, the incursion detection and alarm system effectively provided real-time alerts, ensuring immediate responses. If these incursions had involved an errant member of the public, early notifications would have been critical in preventing accidents and allowing roadworkers to move to safety. 

Speed Compliance
Speed compliance remained an ongoing challenge throughout the trial: 

  • M4 Main Line: Average speed during operational hours was 51 km/h, exceeding the posted limit by 11 km/h. 

  • Homebush Bay Rd On-Ramp: Average speed of 47 km/h, 7 km/h over the limit. 

  • Parramatta Rd On-Ramp: Average speed of 48 km/h, 8 km/h over the limit. 

  • Maximum speed recorded: 87 km/h, exceeding the posted limit by 47 km/h. 

 Although compliance levels were below the required threshold, the data indicated that the visibility of roadworkers played a role in moderating speeds. Vehicles traversing the mainline workzone initially took 8 minutes, later reducing to 3 minutes and 14 seconds as traffic stabilised.  

DIGITAL SIGNAGE COMPLIANCE
The Intellitag system successfully monitored all temporary traffic management signs, ensuring their continued compliance: 

  • 99.90% overall signage compliance achieved 

  • One incident recorded: A "Road Work Ahead" sign fell at 02:26 AM but was reinstated within six minutes. 

 The ability to track sign status in real time allowed for immediate corrective action, ensuring minimal disruption and maintaining clear communication with motorists.

CARBON FOOTPRINT REDUCTION
One of the key benefits observed during the trial was a significant reduction in vehicle movements, leading to lower carbon emissions: 

  • Average reduction in vehicle travel per shift: 22 km 

  • Total carbon savings for the trial: 0.017 tCO2e 

  • Percentage decrease in emissions: 67% 

By eliminating routine manual checks and enabling targeted interventions based on real-time data, the trial demonstrated the environmental advantages of workzone digitisation. The ability to respond only when necessary not only reduces operational costs but also contributes to broader sustainability efforts. 

The M4 Downer Transurban Workzone Digitisation Trial demonstrated the effectiveness of digital technologies in enhancing worksite safety, improving compliance, and reducing environmental impact. These insights reinforce the importance of leveraging real-time monitoring to create more controlled and efficient work environments. 

 
 
 
 
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