Rail infrastructure maintenance is about to undergo a revolution. As digitalization advances, modern assistance systems are being used more and more in track construction and maintenance. At iaf 2025, Plasser & Theurer held a live demonstration of a Unimat 09-4×4/4S E³ that tamped a turnout fully autonomously in just a single pass, without any operating staff.
The demonstration clearly showed the degree to which autonomous track maintenance machines have already developed, as well as the opportunities this technology offers. Further specific steps are set to follow, in order to systematically exploit this potential and continuously increase the value it offers.
The future is autonomous
In their everyday work, infrastructure operators and construction firms face increasing cost pressures, a lack of qualified personnel, and growing demands in terms of safety, quality, and efficiency. It is with these challenges in mind that Plasser & Theurer is pursuing its vision of an autonomous track maintenance machine. The aim is to create an all-round, intelligent system that integrates, automates, and independently shapes the entire maintenance process, from performing work to documenting it.
Working independently
In future, digital systems will allow a single person to fully treat a turnout, reducing labour costs and countering the lack of qualified personnel. At the same time, automated work unit positioning and adaptive control of tamping parameters will ensure consistently high quality. This will enable standardized, repeatable processes, virtually regardless of the operator’s level of experience. As the level of automation increases, the machine will gradually be able to perform more and more of the necessary work steps itself. AI-supported systems will make it possible to automatically generate tamping parameters based on digital specifications and the recorded environmental and condition data. This will reduce the risk of errors, accelerate processes, and ensure consistently high work quality.
Automation levels in track maintenance
Plasser & Theurer is taking a step-by-step approach to automation. This process covers five clearly defined levels, from manual operation to the fully autonomous machine. The scope of functions and degree of automation increase with each level, while the tasks and responsibilities of the operating staff change fundamentally.
- Level 1: manual work process. The machine is controlled entirely by the operating staff, without any automation. Quality and efficiency depend on the experience of the operating staff, who must be experts in the entire work process.
- Level 2: assisted work process. Assistance systems support sub-processes, while responsibility for quality, control, and performing work remains with the operating staff. This reduces the workload for operators, as well as improving ergonomics and the degree of repeatability.
- Level 3: semi-autonomous work process. The machine performs defined work steps autonomously. The operating staff monitor the machine and intervene in the event of faults. Knowledge of systems and processes becomes more important here than manual machine control.
- Level 4: fully autonomous work process. The machine automatically performs all work processes, from the environmental analysis and performing the process to quality assurance. The operating staff are no longer involved and intervene only in an emergency.
- Level 5: fully autonomous machine. All driving and work processes are completely autonomous. There is no cab and no operating staff on site. The machine is controlled and monitored remotely from a central location, leading to maximum safety and efficiency.
Safety first
The system also promises a significant increase in occupational safety. As only one operator will be required in future, who will be working in the protected driving control station throughout, the risk of accidents on the track will fall dramatically. Remote control systems will also contribute to greater safety. Bridging the gap to fully autonomous machines, they will allow machines to be controlled and monitored centrally from a single control centre. Beyond this, the automated unit control will protect not only the operators, but also the infrastructure, by reliably detecting and moving around obstacles like cables or drive systems. This revolution is based on the gradual automation of all sub-systems, from performing individual work steps and independent function checks to detecting and repairing defects.
Expanded documentation
Digital quality assurance is another advantage. The web-based Plasser SmartReporting provides a standardized reporting system that fully records all work and quality parameters. All data can be accessed from anywhere and transferred transparently to the infrastructure manager. This makes it possible to detect deviations early on and significantly reduce the need for reworking. As digitalization increases, information will be collected centrally, prepared in a structured manner, and integrated into other systems. This will form the basis for modern analysis and planning tools, opening up new perspectives for maintenance. The focus will shift from corrective interventions via condition-dependent measures to predictive strategies that forecast the need for maintenance and allow for proactive planning.
From supplier to partner
Increasing automation is also changing the role of the manufacturer. Digital systems call for close cooperation, both during implementation and afterwards. Full-service offers with updates, support, and system adjustments reduce downtimes and accelerate innovations. As a result, manufacturers are going from suppliers to long-term partners, taking increasing responsibility for the systems to both make life easier for customers and ensure stable operations.
The march of automation in track maintenance is fundamentally changing roles and processes alike. A key element of this will be the gradual transfer of control and quality assurance from the operator to the machine. This will make processes more efficient, boost work quality, and significantly increase safety on the worksite – a big step forward for both operating companies and construction firms.
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