A new diamond crossing has been installed at Crossmoor Station to improve reliability, safety and travel times for daily commuter passengers on State-owned the Passenger Rail Agency of South Africa’s (PRASA’s) KwaZulu‑Natal rail network.

The crossing was designed and manufactured by steel and rail company voestalpine Railway Systems subsidiary voestalpine South Africa (VAE SA) at its Isando facility, in Gauteng, and built by construction company Maziya General Services.

The crossing is built on concrete sleepers to provide improved longevity, reduced maintenance and enhanced ride quality for passengers, VAE SA says.

A diamond crossing is a specialised piece of rail infrastructure that enables trains to switch between lines in areas with limited space, which replaces the worn‑out installation that previously sat on wooden sleepers, explains VAE SA business development officer Sizwe Mkhize.

For the communities served by Crossmoor Station and neighbouring areas, the benefits are already being felt. The previous speed restriction of 15 km/h over the old crossing has been increased to 60 km/h now that installation, testing and commissioning are complete.

The improved track geometry also reduces vibration and noise, resulting in a smoother, more comfortable passenger experience, he notes.

Rails, turnouts and diamond crossings ensure safe train movements. Their installation requires a high level of precision, coordination and specialised railway engineering skills to complete.

The installation of the diamond crossing and associated turnouts in Crossmoor was performed by a specialised track installation team using PEM overhead crane and LEM transport cart turnout replacement machines.

The PEM-LEM team managed and executed the placement, gauging, levelling and securing of these elements to ensure the track geometry meets strict operational and safety standards, Mkhize says.

The upgrade is more than a technical renewal, as it restores mobility and opportunity, says Maziya General Services signalling director Heinrich Mostert.

“For years, large sections of the line have been operating on a single track owing to vandalism. Once all upgrades are complete, trains will be able to run in both directions on both lines again – ten minutes apart – instead of one hour apart,” he says.

Further, the design and installation process was tailored to the constraints of the Crossmoor site, says Maziya General Services Perway Department head Kedibone Madiba.

“This is a brownfield environment with limited space, curves and a platform very close to the installation. A diamond crossing is the only viable solution,” he explains.

“We designed everything locally, conducted the surveys, modelled the geometry and worked closely with VAE SA to ensure every component meets the required standards. The result is a system that fits perfectly and performs reliably, even under challenging operating conditions.

“VAE SA’s local presence is critical. When you run a railway, you need immediate support during derailments or faults, and VAE SA has always responded quickly. Their quality and reliability give us confidence,” Madiba adds.

The crossover project forms part of PRASA’s long‑term commitment to rebuilding a safe, modern, dependable public transport system, says PRASA Group Capital Delivery executive Athanacious Makgamatha.

“The Crossmoor upgrade is one step among many, but its impact on the surrounding communities will be profound. Reliable rail transport transforms lives. It connects people to jobs, education and economic opportunities. We’re proud to revitalise a network that many people rely on,” he says.