ETRC Reinvents Rail Maintenance

14/07/2025

Downer has taken a bold, proactive step toward embedding sustainability at the core of rail maintenance—delivering measurable environmental, economic and social outcomes without waiting for regulatory change.

In 2024, our Rail & Transit Systems (RTS) team tackled legacy maintenance practices that led to electronic waste, offshore dependency, and unnecessary carbon emissions. In response, the team launched a data-driven, condition-based maintenance strategy and established an Australian-first facility: the Electronics Test & Repair Centre (ETRC), based at the Cardiff Rail Service Delivery Centre.

Officially opened by NSW Premier Chris Minns, the ETRC enables local testing, repair and refurbishment of complex rail electronics that would otherwise be discarded. It replaces the need for offshore repairs or full-system replacements, cutting costs, emissions, and material waste.

The results are substantial. Across Waratah fleet overhauls alone, the ETRC enables the recovery of more than 9,000 printed circuit boards (PCBs)—diverting 6.9 tonnes of e-waste and reducing CO₂ emissions by approximately 89%.

_{A printed circuit board}

The ETRC goes beyond sustainability—it also supports local jobs, skills development, and sovereign capability. Technicians, engineers, apprentices and graduates now gain hands-on experience with industry-leading tools like digital emulators, simulators, and automated testing rigs.

Recognition of this initiative continues to grow:

• Finalist for the 2025 Sustainability Excellence Award at the Australasian Rail Industry Awards
• Showcased at AusRAIL PLUS 2025, Australia’s largest rail industry event
• Featured in Train Rescue Down Under (Episode 9) on 7Mate, spotlighting how innovation and circular economy thinking are reshaping the future of rail

As sustainability becomes non-negotiable across the sector, Downer’s approach proves that innovation in operations can unlock value far beyond compliance—delivering impact today, and building capability for tomorrow.

_{The team in the ETRC}