Hungarian construction firm V-Híd already has a track renewal machine from Plasser & Theurer, which has now been joined by a new Plasser AssemblyLiner 1020. The system is based on the successful experience with the SMD-80 series, but was completely redesigned to respond to modern requirements.

All main work tasks combined in a single process

The crawler running gear enables continuous track renewal, regardless of the effects of weather. It ensures a steady forward motion, even in the event of rain or wet rails. All of the central maintenance tasks occur in a single work process within the machine system:

• Removing the rail fasteners (track gauge rods)
• Removing the old rails
• Dismantling the old sleepers
• Creating a stable sleeper bed
• Laying the new sleepers
• Installing the new rails
• Continuously supplying and removing material

If an old sleeper falls apart during removal, an integrated expulsion unit can push it out to the side so that the workflow can continue uninterrupted.

This assembly-line method does not require the adjacent track to be closed. A life cycle assessment shows that it increases the sustainability of large worksites compared to conventional methods. The Plasser AssemblyLiner covers three working modes in one: track renewal, removal, and laying. The newly developed design enables this without the need for a machine conversion.

Rethinking machine control with Plasser WorkingView

One of the most significant steps forward in the Plasser AssemblyLiner 1020 can be found in the revised cab and control design. The new cab is 2.2 metres in height, offering much more space. The workstation has been redesigned with ergonomics in mind to make work safer.

High-resolution cameras deliver razor-sharp images of all working areas and transmit them to five monitors inside the air-conditioned cab. The Plasser WorkingView system allows operating staff to control the work units from a safe distance. This reduces physical strain and gives them a better overview of the entire worksite. The cameras cover a range of perspectives, from steering the crawler running gear via the view of the track with automatic direction switching to monitoring the sleeper pick-up units, excavating chain, sleeper laying, and the old-sleeper collecting system. When laying new sleepers, further camera images provide a view of the plough blade with screw conveyor for creating an optimum sleeper bed. Indicator lines act as a visual aid for more precise handling when removing the old sleepers.

Find out more in our technology brochure "New track with the assembly-line method".

The cab is easily accessed via the access steps with safety platform. This new, more user-friendly workstation reduces stress factors and makes work safer, therefore increasing the efficiency of the track maintenance process.

All about material logistics

As well as precisely coordinated work units, material logistics is a crucial part of getting the most from the Plasser AssemblyLiner 1020. A pair of gantry cranes provide a continuous supply of new sleepers and rapidly handle the old ones, so that the workflow is never interrupted. Assembly-line technology, combined with improved logistics, minimizes idle times and makes sure that lots can be used for renewal, removal, and laying in a cost-effective way according to plan.

The clever integration of material logistics accelerates track renewal, while also increasing the quality of the track itself. By gently installing new sleepers and rails, combined with an ideal sleeper bed, the Plasser AssemblyLiner 1020 creates the best possible foundation for tracks that stay safe and stable for the long term. The machine also allows for flexible adjustment to varying worksite conditions and superstructure forms, making it suitable for a range of projects.

For operating companies, the benefits are clear. The assembly-line method reduces interruptions in rail traffic by making better use of track possessions. The working conditions for operating staff are better. And the improved material input with reduced idle times improves sustainability.

Plasser & Theurer trained the machine crew in Salgótarján, Hungary, in the autumn of 2025. By the following spring, the Plasser AssemblyLiner 1020 was already at work on Hungarian worksites.