A strong partnership for a strong network

DB InfraGO AG has purchased 13 CatenaryCrafter 15.4 E³ machines, setting new benchmarks in overhead contact line maintenance. This clever three-way partnership between operating company, service ECM, and manufacturer combines vehicle technology, availability, and financing into a package that sets an example for the future.

The CatenaryCrafter for DB InfraGO AG offers all the necessary work units for efficient deployment on overhead contact line systems. The crane and elevating work platform enable greater reach and allow operating staff to access difficult-to-reach areas such as masts, tunnel walls, or other rail infrastructure.

The signing of the contract in December 2025 marked the start of one of Germany’s most significant procurement processes for modern catenary installation and maintenance machines. DB InfraGO AG ordered 13 Plasser CatenaryCrafter 15.4 E³ vehicles via a newly developed lease-purchase model. The machines will be delivered from the end of 2028.

The project is based on a clearly defined three-way partnership. DB InfraGO AG will take operative control of the machines and will assume ownership of them automatically once the two-year lease period ends. Plasser Robel Services (PRS) acts as the buyer and lessor, and provides the full-service maintenance package as a full ECM organization as detailed in the contract. As the manufacturer, Plasser & Theurer takes responsibility for the development, production, and technical layout of the vehicles.

ECM tasks

The tasks of an ECM can be divided into four clearly defined functions:

ECM 1 – maintenance management

This function covers the overall responsibility for ensuring the safe condition of the vehicles. It coordinates all ECM sub-functions, manages the maintenance processes, and takes care of systematic risk management.

ECM 2 – maintenance development

This function covers the creation and continued development of technical maintenance tasks. It ensures that all activities are performed at a high level of safety and is responsible for managing all the relevant data.

ECM 3 – vehicle fleet management

This function controls the operative implementation of maintenance. It grants technical authorizations for workshops and monitors the quality of the work performed. A range of inspection and audit measures ensures compliance with specifications.

ECM 4 – maintenance delivery

This function controls the practical execution of maintenance measures. This includes servicing, repair, documentation, and the formal approval of the vehicles for operation once the work is complete.

This structure is also in use internationally. At its site in Purkersdorf, Austria, Plasser & Theurer acts as ECM for Austrian Federal Railways (ÖBB) and has an ÖBB workshop permit – further proof of high service quality throughout the entire life cycle.

“We have enjoyed a successful business relationship with Deutsche Bahn for 67 years. Many important track construction technologies were first put into operation on DB tracks. In total, around 740 machines have been delivered to DB so far, with over 150 of those still in operation. I am very pleased at how this current order further strengthens our long-term collaboration”, emphasizes Johannes Max-Theurer, CEO of Plasser & Theurer.

Technology for short track windows and heavy rail traffic

The procurement is DB InfraGO’s response to the challenging conditions in maintenance management. Shorter track possessions, busier timetables, and the heightened demand for maintenance caused by increased operations call for maintenance vehicles that are as flexible as they are capable.

The trimodal drive system draws energy for traction and the work units via either the overhead contact line, the underfloor battery, or the diesel-electric powerpack. Staff can switch between the various energy modes during operations.

Designed for modern maintenance

The CatenaryCrafter was developed precisely for these conditions. The vehicle is designed for inspecting, constructing, and servicing overhead contact line systems, as well as for intervening quickly in the event of a failure.

With a top speed of 120 km/h, these machines can get to where they are needed quickly and integrate easily into day-to-day rail traffic.

Sustainable financing

Plasser & Theurer does not just stand out thanks to its technical expertise, but also due to its broad knowledge of export financing. We have made it our goal to provide our customers with comprehensive advice and support in this area, as financing is extremely complex and requires customized solutions. A wide range of instruments, together with our broad network of banking partners, allows us to respond appropriately to the commercial needs of our customers.

The lease-purchase agreement for the project with DB InfraGO is an all-new model that was developed together by the project partners. These include DAL (Deutsche Anlagen-Leasing GmbH & Co. KG) as structurer and regional bank BayernLB as refinancer.

The financing covers a construction period of four years, with a further two years of post-delivery financing. At the end of the contract period, DB InfraGO will take full ownership of the vehicles. The financing is provided via a special purpose entity of DAL and meets the requirements of the BayernLB Sustainable Financing Framework.

Sustainable drive systems for high flexibility

Thanks to E³ technology, the vehicles can be operated using three energy sources: green electricity from the overhead contact line or battery, and diesel-electric mode for longer working periods without an external power supply. Even this latter operating mode can be made environmentally friendly through the use of hydrotreated vegetable oil as a fuel. The E³ drive system is virtually silent during work and travel. This makes life easier not only for the operating staff when working in tunnels, for example, but also for lineside residents.

Safe, versatile, and ergonomic

The machines are fitted with a railway crane for greater reach and a fully pivoting elevating work platform that allows staff to work safely in exposed and difficult-to-reach areas like the tops of masts or cross spans. Equipment for winter operations can be integrated as an optional extra, expanding the range of applications and ensuring smooth railway operations.

The spacious crew area increases crew comfort and offers a protected space for breaks or office work.

Virtually all tasks can be performed from within the vehicle. A protected working environment, modern safety systems, on-board workshop, and a fully equipped crew area with sanitary facilities minimize the need to go out into the danger zone. The CatenaryCrafter can comfortably accommodate up to 11 people, even during longer periods of transfer travel, making deployment planning easier.

ECM expertise for high availability

DB InfraGO AG and PRS have agreed a full-service maintenance contract for the first two years of operation. Acting in the role of certified Entity in Charge of Maintenance (ECM), PRS will take full responsibility for maintenance and maximizing the machines’ availability for day-to-day operations.

The large on-board workshop allows important preparatory work to be carried out directly on site.

Lease-purchase plus service – a model for the future

The selected lease-purchase agreement for financing the vehicles is an all-new model that was developed together by the project partners. It is the first financing model to combine investment, operations, and service in an integrated approach. This model provides peace of mind for all project partners, delivering economic security for high-volume projects while maximizing technical availability.

It represents a potential blueprint for future large-scale infrastructure projects, one that is flexible, sustainable, and cooperative.