GapSafe - A safety system for high level train maintenance platforms

GapSafe is an automated safety system for high level maintenance platforms that safely closes the gap between the work area and the edge of the maintenance platform.

GapSafe can quickly close gaps of varying sizes without causing damage to the train or the maintenance platform.

The innovative system prevents personnel, tools, and equipment from dropping down the “gap” eliminating injury to workers and damage to rolling stock.

GapSafe removes the need for restrictive Mansafe harness and wire systems allowing personnel to move freely.

System features

  • GapSafe works by inflating flexible bladders that are positioned where required along the length of the maintenance platform. The action of inflating the bladder fills the gap between the platform and the train itself.
  • GapSafe can be automatically activated by interlinking with a working platform entry system. When entry is gained to the working maintenance platform the bladders will automatically inflate to fill the gap between the platform and the train. Once the working platform is exited the GapSafe bladder will automatically deflate.
  • GapSafe can also be interlinked with any other existing automated safety or business management system already in place.
  • GapSafe can also be operated manually where existing linking systems are not available.
  • GapSafe is made from a very robust material making it resilient to cutting or wear and tear in normal use.
  • The GapSafe bladder is operated by a simple control system with an easy to use touch screen interface. The GapSafe inbuilt diagnostic checking function enables the user to test system functionality and to diagnose operating faults

Safety features

  • GapSafe permits freer maintenance operations to the train that would otherwise be restricted by the necessity to harness maintenance teams.
  • GapSafe prevents persons, tools and equipment from falling between the train and maintenance platform preventing risk of injury to persons and damage to plant and equipment.

Operational features

  • Once inflated, GapSafe constantly monitors and maintains the pressure within the bladder to ensure the gap between the train and the maintenance platform remains closed.
  • When GapSafe is deactivated the air is vacuumed out of the bladder to ensure that the bladder sits flat against the bladder retainer preventing any risk of obstruction to the train, maintenance platform and train movements.
  • GapSafe incorporates a beacon to give a visual representation of operating status. When GapSafe is activated and is in the process of being inflated to its required operating pressure a green light positioned at the control panel flashes on and off at a slow rate until pressure is reached. Once GapSafe has reached its operating pressure the beacon remains illuminated.
  • If, whilst at operating pressure, there is a pressure fault meaning that pressure cannot be maintained within the bladder the control system will display a visual alarm by repeated flashing of the beacon at a fast rate. In addition to this an audible signal will sound as an added safety warning to alert personnel that GapSafe is not operating correctly.


  • Each GapSafe system is supplied and installed by our trained fitters to ensure the system is correctly installed and commissioned.

Prior to installation a survey of the area will be undertaken. This is to identify the optimum positioning of the control panel and warning systems and method of activation. As well as ascertaining the size, number and length of bladders to be installed.