Unipart Rail is delivering transformative innovations for construction, maintenance and renewal projects.
The global rail industry is facing unprecedented challenges. As rail networks recover from the pandemic, they must also navigate global conflicts, inflationary pressures, labour shortages and supply chain disruptions. These factors have fundamentally altered the cost dynamics of construction work. Despite increased funding, the availability of resources and materials has not kept pace and ageing infrastructure is increasingly strained by climate change.
Changing commuter patterns, with fewer regular commuters and more weekend travellers, add another layer of complexity. This shift requires transportation systems to adapt to irregular and unpredictable usage patterns, ensuring that services are reliable and efficient at all times. It also necessitates continuous maintenance and upgrades to infrastructure to handle varying loads, which can be challenging to manage.
In response, governments worldwide are making substantial investments in rail infrastructure, reflecting a shared commitment to reliable and safe transportation networks. From Network Rail’s £44 billion CP7 initiative in the UK to Ireland’s €35 billion plan, the Biden-Harris administration’s $66 billion investment, Canada’s Go Expansion project, Australia’s 68% increase in rail funding, and India’s 7 trillion rupee modernisation plan, the message is clear: delivering rail projects safely, efficiently and reliably is paramount.
The imperative for innovation
The surge in railway traffic is exerting immense pressure on infrastructure managers and maintenance contractors. Heavier and more frequent trains accelerate track wear and tear, necessitating meticulous and continuous maintenance to ensure reliability and safety. However, the limited time available for maintenance due to increasing train operations exacerbates the situation, amplifying the need for innovative approaches.
The rail industry must adopt smarter strategies to optimise available track time while maintaining peak performance levels. This necessitates new working patterns that enhance efficiencies and reduce possession times, allowing operators to address the dual challenges of rising traffic volumes and the need for consistent maintenance.



The cost of failure
Infrastructure faults can lead to significant financial losses and disrupt passenger and freight services, affecting commuters, businesses and economies globally. Such disruptions erode public trust in rail services and undermine the industry’s reputation for reliability and efficiency. A 2019 report by the Rail Delivery Group highlighted that infrastructure faults cost the UK rail industry a staggering £1 billion. This underscores the universal importance of maintaining railway tracks in optimal condition.
The financial repercussions of construction, maintenance and renewal delays extend beyond immediate costs, including compensation claims, loss of productivity and potential damage to brand reputation.
Therefore, prioritising proactive maintenance, infrastructure upgrades, and the adoption of advanced monitoring technologies is imperative for rail networks worldwide. By investing in comprehensive maintenance programs and predictive maintenance strategies, the global rail industry can mitigate future disruptions, enhance operational efficiency and bolster competitiveness.
High output methodologies
Over the last decade, rail networks have invested heavily in specialist on-track plant machinery to deliver rail renewals. These advanced technologies and techniques result in higher-quality track installations, improved track stability and enhanced overall safety and reliability. Additionally, high-output track renewal methods can increase railway line capacity by improving track layouts, alignment and reducing speed restrictions, accommodating growing passenger and freight demands.
Rapid completion of track renewal projects minimises service disruptions, particularly in busy rail corridors and urban areas, where interruptions can have significant economic and social implications. These methods are also versatile, adaptable to various track configurations and conditions, and often incorporate environmentally friendly practices, such as using recycled materials and minimising waste generation.
However, high-output track renewal methods present challenges, including high capital and operational costs, logistical constraints, lack of flexibility, the need for skilled workers, and environmental impact. Their large size poses challenges in restricted areas and their energy and resource demands can have a greater environmental impact compared to traditional methods.
Revolutionary machines for modern railways
Recognising these challenges, Unipart Rail and Thomson Engineering Design Ltd are working in partnership and are delivering a range of transformative, sustainable and performance enhancing solutions for rail construction, maintenance, and renewal projects, which are redefining industry standards and elevating operational efficiencies across the global rail market.
Together we are introducing a new range of machines designed to overcome the limitations of traditional high-output methods, delivering high performance, safety and efficiency, whilst substantially reducing costs and carbon.
The new range includes:
Sleeper Layer: Providing delivery rates of up to 1000 sleepers/ties per hour, and offering a variety of options including automatic steering, remote condition monitoring and diagnostic support. The Sleeper Layer is exclusively available to hire from Story Plant in the UK.
Rail Handler: A versatile, multi-purpose machine offering a variety of applications and benefits for installing, removing and transposing rails.
Rail Clipper: A unique self-propelled, road-rail clipping machine with applications in rail maintenance and track renewals operations.
The key features of these groundbreaking machines include:
- Increased safety: Our new machines enhance safety by minimising human involvement and potential hazards. By removing the operator from the machine, the risk of accidents is significantly reduced.
- Cost Savings: With lower capital investment and operational costs, in addition to reduced labour requirements and enhanced productivity, our machines enable significant cost savings for rail operators.
- Efficiency: By automating repetitive tasks and optimising workflows, our machines drastically reduce the time required for rail projects, leading to increased efficiency and faster project completion.
- Rapid deployment: The new machines are designed for rapid deployment, with shorter possession times and easy transportation to sites without additional equipment. This allows work to start immediately, increasing productivity during possession periods.
- Advanced technology: Incorporating state-of-the-art digital technologies, such as automation, our machines offer unparalleled precision and accuracy in rail maintenance and renewal tasks, leading to high quality, sustainable infrastructure and safer working environments.
- Versatility: Designed to handle a wide range of tasks, from track renewal to ballast maintenance, our machines offer versatility and adaptability to meet the diverse needs of the global rail industry.
The future of the industry
The rail industry stands at a critical juncture, requiring innovative solutions to address the growing challenges of maintenance and renewal. The partnership between Unipart Rail and Thomson Engineering Design Ltd offers a transformative approach, delivering solutions that are more productive, safer and sustainable. By embracing modern technologies and advanced engineering principles, we are empowering rail operators and contractors to achieve unprecedented levels of performance and reliability and are paving the way for a new era in rail maintenance, ensuring that rail networks worldwide are ready for the future.


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All images credit: Unipart Rail