A key objective of Rail4Climate is to put research findings into practice more quickly. Funding is therefore primarily provided for projects that test prototypes under realistic conditions, facilitating the transition from development to operational use. The aim is to bring innovations to market more quickly and to measurably contribute to the transition towards sustainable mobility.

A consortium – comprising Plasser & Theurer, Schuster + Schuster Traffic Infrastructure Consulting GmbH, and ÖBB Infra – has been awarded a Rail4Climate grant. Over the course of a three-year project, the focus will be on two main work packages:

• data-based turnout maintenance in a safe environment
• further automation of tamping machines

Data-based maintenance for greater availability

Advances in turnout measurement form the basis for data-based – and therefore more efficient – maintenance. The aim is to assess the condition of the turnouts, identify damage profiles, and automatically determine the appropriate measures.

It is not just a matter of determining the best time for tamping. Any signs of wear or damage requiring intervention must be identified. Interventions include retightening bolts in the turnouts, reworking rail joints, or grinding in and around common crossings. Inspections for planning these measures are often performed manually and require assessing the track on foot. Using a track inspection vehicle and digital planning for measuring, the frequency of track assessments on foot can be gradually reduced. This improves safety, as staff are kept out of the danger zone, and increases efficiency by reducing the time taken to inspect the turnouts.

The path to data-based maintenance planning involves several steps. First, the turnouts are measured using Plasser & Theurer track inspection vehicles. The equipment used includes, among other things, a laser-based measuring system for turnouts and crossings, a video-based inspection system, and systems for inertial track geometry measuring. Compiling a standardized damage catalogue for turnouts plays a key role in the research project. The anomalies detected in the measuring data are categorized accordingly. The next step is an analysis of the urgency and impact of the identified damage profiles.

Infrastructure managers develop maintenance measures for turnouts primarily on the basis of experience, drawing on the expertise of the relevant specialists. The process outlined here marks a significant step towards data-based turnout maintenance. The aim is to record and assess defects in a reproducible manner based on the standardized list of defects. This is done to be able to correct them before they can lead to more serious issues or unplanned service disruptions. Furthermore, by combining maintenance actions, pollutant emissions and track possession durations can be reduced. Optimized turnout maintenance makes a significant contribution to the high availability of the track infrastructure.

Automation of tamping machines

The second focus of the research project is on continuing to automate tamping machines. A milestone was presented at iaf 2025: for the first time, Plasser & Theurer showcased an autonomous turnout tamping operation using the Unimat 09-4x4/4S E³, with no operators in the work cab.

The next step is to develop this concept further. The focus is on continuing to extend Plasser TampingControl. Already today, the system automatically adjusts the tamping pressure to the current conditions on the track. A future goal is to automate all relevant tamping parameters, such as squeezing times or the number of tamping cycles. The aim is to achieve consistently high tamping quality – regardless of local conditions.

​The aim of the current development is to apply this level of automation to the track-laying process as well. This will make it possible to carry out a complete tamping process, even on ballast-covered track, based on the current conditions. This also ensures that obstacles not included in the turnout layout are reliably detected, enabling an immediate response to local conditions. Measuring turnouts or entering turnout data is not required.

An event-based camera detects even the slightest movements in the ballast and makes the sleepers and rails lying beneath it visible. This allows the tamping tines to achieve precise penetration of the sleeper crib.

Innovations that make a difference

Through the projects funded by Rail4Climate, the consortium is demonstrating how digitalization and automation can deliver tangible benefits for the rail industry. Innovative technologies enhance safety, enable more efficient use of resources, and improve the reliability of the infrastructure in the long term. Support from the funding programme gives these developments an extra boost, enabling an even quicker transition from research to real-world application.