Hi-rail trucks play a vital role in modern rail maintenance and construction. These versatile vehicles allow operators to travel seamlessly on both road and rail, providing flexibility, efficiency, and cost savings for rail projects.
But converting a standard truck into a reliable hi-rail vehicle is a highly technical process that requires expert engineering and precision. At Mitchell Railgear, we specialise in complete hi-rail truck conversions, delivering safe, compliant, and purpose-built rail vehicles for clients across Australia.
What Is a Hi-Rail Truck Conversion?
A hi-rail truck conversion involves modifying a conventional road vehicle so it can operate on railway tracks as well as on regular roads.
This is achieved by installing specialised rail guidance systems, braking equipment, and safety components that allow the vehicle to:
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Enter and exit rail tracks
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Travel safely along rail lines
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Perform maintenance and inspection tasks
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Carry tools and equipment directly to work sites
The result is a dual-purpose vehicle that greatly improves productivity for rail contractors and maintenance teams.
Why Convert a Truck to Hi-Rail?
Hi-rail vehicles are essential for many rail industry applications, including:
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Track maintenance
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Signal and communications work
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Overhead wiring projects
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Rail inspections
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Emergency response
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Infrastructure construction
Converting an existing truck to hi-rail capability is often more cost-effective and practical than purchasing dedicated rail-only machinery.
The Hi-Rail Truck Conversion Process
At Mitchell Railgear, we follow a structured and professional conversion process to ensure every vehicle meets the highest standards of performance and safety.
1. Initial Consultation and Assessment
Every project begins with a detailed consultation to understand:
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The type of truck being converted
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Intended rail applications
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Load and towing requirements
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Site conditions
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Client specifications
This allows us to recommend the most suitable hi-rail system and configuration.
2. Engineering and Design
Our experienced engineers develop a custom conversion plan tailored to your vehicle and operational needs.
This stage includes:
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Structural analysis
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Equipment selection
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Mounting design
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Brake system integration
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Compliance planning
All designs are created to meet Australian rail safety standards.
3. Rail Gear Installation
The core of any hi-rail conversion is the installation of rail guidance equipment, including:
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Front and rear hi-rail wheel assemblies
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Hydraulic or mechanical lift systems
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Rail wheel alignment systems
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Locking mechanisms
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Control systems
These components allow the truck to safely engage with the rail track while maintaining road functionality.
4. Braking and Safety Systems
Safety is critical in hi-rail operations. We install and integrate:
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Rail-compatible braking systems
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Emergency braking controls
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Rail guidance safety features
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Lighting and signalling equipment
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Warning devices
This ensures full compliance and safe operation in all rail environments.
5. Custom Modifications
Depending on your needs, we can also add:
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Toolboxes and storage
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Cranes or lifting equipment
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Work platforms
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Custom trays
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Electrical systems
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Communication equipment
Every conversion can be fully customised to suit your specific job requirements.
6. Testing and Certification
Before any vehicle leaves our workshop, it undergoes:
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Comprehensive mechanical testing
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Rail performance testing
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Safety inspections
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Compliance checks
We ensure the converted truck is fully operational, safe, and ready for immediate use on the rail network.
Vehicles We Can Convert
Mitchell Railgear can convert a wide range of vehicles, including:
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Light commercial trucks
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Heavy-duty trucks
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Utility vehicles
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Service vehicles
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Specialty maintenance trucks
No matter the make or model, we can design a hi-rail solution to match.
Benefits of a Professional Hi-Rail Conversion
Choosing Mitchell Railgear for your conversion delivers many advantages:
✔ Increased operational efficiency
✔ Access to remote rail locations
✔ Reduced project costs
✔ Improved flexibility
✔ Custom-built solutions
✔ Full safety compliance
✔ Reliable, long-lasting equipment
Australian Conditions – Built Tough
Rail operations in Australia demand equipment that can handle:
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Extreme weather
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Long distances
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Heavy workloads
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Rugged environments
Our hi-rail conversions are engineered specifically for Australian conditions, ensuring dependable performance year after year.
Ongoing Support and Maintenance
Our service doesn’t stop after installation. We also provide:
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Routine servicing
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System upgrades
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Repairs and spare parts
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Technical support
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Fleet maintenance programs
Mitchell Railgear is your long-term partner in hi-rail vehicle performance.
Choose the Hi-Rail Conversion Experts
A hi-rail truck conversion is a major investment, and it needs to be done right the first time.
With years of experience and a reputation for quality, Mitchell Railgear is a trusted leader in hi-rail conversions across Australia. We combine expert engineering, high-quality components, and proven processes to deliver vehicles you can rely on.
Get Started Today
If you’re looking to convert a truck into a fully functional hi-rail vehicle, our team is ready to help.
Contact Mitchell Railgear today to discuss your requirements and receive a customised conversion solution.
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