Retrofit in less than four months

After 13 intense years of operation, it was high time for a refurbishment of STRABAG AG’s universal tamping machine. As we collaborate with the company on an ongoing basis, we talked to them last year about which options were possible. It was clear from the get-go that it would be ideal to perform a retrofit while refurbishing the machine.

A job for the team in the new Life Cycle Service Centre in Linz

The new Competence Centre in the main works in Linz was set up to create ideal working conditions for large projects such as retrofits. The space that is available is also perfect for larger machines, and the technical equipment is state-of-the-art. Plus, the team that works here has direct access to all of the machine documentation, with the machines being built just a few metres away.

In December 2023, STRABAG AG’s Unimat 09-32/4S Dynamic arrived in Linz, where it was cleaned from top to bottom. Afterwards it went to the workshop, where all the preparations for the project had been made.

Standard refurbishments combined with important updates

With retrofit projects, it is essential that a standard refurbishment is used at the same time to perform technical upgrades on the machine. In the case of STRABAG AG’s Unimat 09-32/4S Dynamic, the result was a project that focused on the following: replacing the tamping unit with a refurbished one featuring frequency control, replacing the digital measurement recording system (DRP) with the latest version, and installing the SmartALC Automatic Guiding Computer. We took the opportunity to replace the rear-view mirrors with rear-view cameras and to install new operator seats, which have armrests with modern function switches.

Teamwork with the customer and within the group of companies

Within the Plasser Group, Plasser Robel Services (PRS) has experienced staff that specialize in reconditioning tamping units, which means that PRS in Munich took care of this part of the job. We worked closely with the customer during the project, with STRABAG AG employees servicing the DGS unit on-site themselves. This provided an additional benefit: the employees were able to see the updates being performed first-hand and familiarize themselves with the systems.

Roll-out after less than four months

Although the project took place over the Christmas holidays, all work could be performed according to plan. The machine was handed over again on 9 March 2024, less than four months after it started. As Peter Schuckert notes, “This incredibly short time frame for a project like this was great for us, because every day we’re in operation means revenue. The Life Cycle Service Competence Centre in Linz is of course a major plus. It’s easy and efficient to work in this kind of infrastructure. However, I personally believe that our ongoing collaboration also plays a role. You know from the outset what is realistic and you can also rely on your partner’s flexibility in case something comes up.”

A retrofit project according to plan

Shortly after the handover, STRABAG AG’s Unimat 09-32/4S Dynamic was already back on its way to Graz, where track maintenance had to be carried out and several turnouts on the construction site had to be tamped. Once again, Plasser & Theurer has shown that retrofits not only meet the highest technical standards, but also that project management runs like clockwork ‒ exactly the way customers want it. As Alexander Pap, project manager at Plasser & Theurer notes, “The project went exactly the way we imagined. It clearly showed that we have the perfect prerequisites for high-quality and timely retrofits with the new infrastructure, qualified staff, and direct collaboration with the design engineers in Linz.”