# Classic Coachworks

> Classic Coachworks Pty Ltd is an Australian engineering and manufacturing company in Mortdale, Sydney, founded in 1997 (ABN 61 079 162 155). It designs, manufactures and refurbishes rail interiors — seating, fire-retardant foams, GRP, trim, blinds and upholstery — for nearly every passenger fleet in Australia, and applies the same materials engineering to defence, bus, marine, aerospace and healthcare. One Sydney site covers the full life of an interior component, from 3D scan and mould design through foam moulding, cut-and-sew and GRP to fleet-wide refurbishment and weekly depot maintenance.

## About

Classic Coachworks operates from a single facility that handles design, reverse engineering, manufacturing and fleet-scale refurbishment in-house. Notable programs include the interior overhaul and Technology Upgrade Phase 2 (seating and GRP) of 446 Tangara double-deck carriages, full interior seat refurbishment of 53 OSCAR four-car sets, and support for 15+ passenger fleets across NSW, Queensland and Victoria (OEM supply, refurbishment and depot programs). The company has hosted 60+ mechanical engineering interns over ten years with UNSW, the University of Sydney, UTS and Western Sydney University.

Its impact-absorbing foam engineering also underpins Kradal, a flooring brand for aged care and healthcare.

- Location: 14A Hearne Street, Mortdale NSW 2223, Australia
- Phone: +61 (02) 9533 6565
- Email: info@classiccoachworks.com.au

## Fire performance & compliance

Materials are tested against the standards used to assess rail tenders:

- EN 45545-2 — Hazard Levels HL2 / HL3
- AS 1530
- BS 6853
- CCW R201 — in-house GRP resin, compliant to EN 45545-2 HL2, approved by Queensland Rail and Sydney Trains for new parts and repairs
- In-house vertical burn testing of fabrics before installation

## Services

- [Services overview](https://www.classiccoachworks.com.au/services): Design, manufacturing, trimming, rolling stock refurbishment and reverse engineering under one roof.
- [Innovative Product Design](https://www.classiccoachworks.com.au/services/product-design): Product and component design for rail and industrial interiors.
- [Cutting Edge Manufacturing](https://www.classiccoachworks.com.au/services/manufacturing): Custom foam formulations tuned for fire retardancy, hardness and fatigue resistance; moulded silicon and integral-skin foams; GRP tooling and production; industrial cut-and-sew upholstery.
- [Industrial Trimming Solutions](https://www.classiccoachworks.com.au/services/trimming): Industrial cut-and-sew and trim for transport interiors.
- [Rolling Stock Refurbishment](https://www.classiccoachworks.com.au/services/rolling-stock): Complete interior overhauls, depot support and standing maintenance programs at fleet scale.
- [Reverse Engineering](https://www.classiccoachworks.com.au/services/reverse-engineering): 3D scanning and model creation for obsolete parts — cushions, backrests, armrests, handles — including mould design and manufacture where the OEM no longer exists.

## Products

- [Products overview](https://www.classiccoachworks.com.au/products): Rail and industrial interior products manufactured in Sydney.
- [Kradal Impact-Absorbing Foam](https://www.classiccoachworks.com.au/products/kradal): Impact-absorbing floor underlay engineered to reduce fall-injury likelihood; Assisted Living Product of the Year, Asia Pacific Eldercare Innovation Awards 2026.
- [Safety and Fire-Retardant Products](https://www.classiccoachworks.com.au/safety-fireretardancy): EN 45545-2 compliant materials spanning the full interior, plus safety nets supplied to rail depots Australia-wide.
- [Seat Foam](https://www.classiccoachworks.com.au/foamproducts): Custom and fire-retardant seat foam, including reverse-engineered formulations.
- [Upholstery](https://www.classiccoachworks.com.au/upholstery): Seat covers and upholstery, design through cut-and-sew.

## Company

- [Home](https://www.classiccoachworks.com.au): Company overview, fleet experience and capabilities.
- [Our Mission](https://www.classiccoachworks.com.au/mission-statement): Company mission and approach.
- [Projects](https://www.classiccoachworks.com.au/projects): Rail fleet programs across Sydney Trains, NSW TrainLink, Queensland Rail, Transport Victoria and light rail.
- [Contact](https://www.classiccoachworks.com.au/contact): Enquiries, quotes and location details.

## Resources

- [Capability Statement (PDF)](https://www.classiccoachworks.com.au/_files/ugd/612afe_77e6e69b18bf40528f5e7127f5f5ecc3.pdf): Detailed overview of capabilities, compliance and fleet experience.
- [Kradal](https://www.kradal.com/): Sister brand — impact-absorbing and acoustic flooring for aged care, healthcare, disability and gymnasium sectors.

## Optional

- [Internship](https://www.classiccoachworks.com.au/internship): Mechanical engineering internships, run in partnership with UNSW, the University of Sydney, UTS and Western Sydney University.