Suppliers incorporate AI, data and other high-tech to determine track conditions

Compiled by Julie Sneider, Senior Editor

Geismar

As railway networks expand and age, the need for precise, efficient and reliable track inspection becomes increasingly critical. A long-established name in railway maintenance, Geismar has developed a suite of measurement tools that address the technical challenges of modern rail infrastructure monitoring, company officials said in an email.

Geismar’s portfolio includes both manual and automated systems designed to capture key track parameters such as gauge, cant, superelevation, twist and rail inclination. These measurements are essential for ensuring track geometry remains within safety tolerances and for identifying early signs of wear or deformation, Geismar officials said.

Among the company’s notable tools is the GARNET series, which includes electronic track gauges capable of high-precision geometry measurements. The GARNET-DL variant adds data logging and analysis features, enabling longitudinal monitoring of track conditions.

The AMBER system offers a walk-behind solution for collecting multiple parameters in a single pass, ideal for light-rail and road-rail applications.

For rapid, on-site assessments, RCA and RCFF gauges offer lightweight, durable options. The JET device adds digital rail inclination measurement with Bluetooth connectivity, facilitating real-time data transfer.

More advanced systems like the VIGILIS 400 and Eye Dragon integrate ultrasonic inspection and catenary measurement, supporting comprehensive infrastructure diagnostics.

The company’s tools reflect a broader trend in railway maintenance: the integration of digital technologies with field-proven engineering, Geismar officials said. By enabling data-driven decision-making, the tools contribute to safer and more efficient rail operations, they said.

Holland LP

Holland’s autonomous UGMS system can be installed under the locomotive to provide track geometry and rail profile measurements without the need for a dedicated vehicle, track time or headcount.

Holland LP

Holland’s Argus^® technology enables precise geometry inspections across various applications, from TrackSTAR^® track strength testing to portable inspections and locomotive unattended geometry measurement systems (UGMS).

The Argus 2.0 Track Inspector, Holland’s portable track inspector system, offers three applications to deliver real-time track geometry and rail profile measurements. Any conventional hi-rail vehicle can be quickly converted into an inspection vehicle by attaching the system to a standard hitch mount. This system features a noncontact encoder and is available with three different software options: “attended operation,” “heads-up” and “autonomous.”

Holland’s locomotive UGMS/ATGMS system also has been driving the market for track inspection. The autonomous system is installed under the locomotive to provide track geometry and rail profile measurements without the need for a dedicated vehicle, track time or headcount.

The system allows track measurement at track speed and under an operational load environment. It enables continuous testing along critical network corridors while being integrated into revenue service, Holland officials said.

Installation of the UGMS system requires no welding or drilling and uses the locomotive’s power, they said.

Loram Maintenance of Way Inc.

Recent upgrades to Loram’s Aurora system focused on increasing hardware reliability and delivering actionable intelligence for tie replacement planning.

Loram Maintenance of Way Inc.

Aurora tie inspection continues to be an industry leader in automated tie evaluation, according to Loram Maintenance of Way Inc. officials. Recent Aurora upgrades focused on increasing hardware reliability and delivering actionable intelligence for tie replacement planning.

Aurora is undergoing an upfit with enhanced cooling systems designed for continuous operation in high-temperature, high-dust environments common across North American railroads, Loram officials said. The improvements are designed to stabilize core electronics and ensure consistent performance during long-range deployments.

Ruggedized enclosures protect high-resolution cameras, lasers and processing units from vibration and environmental contaminants, significantly reducing maintenance intervals and improving operational uptime, company officials said.

At the same time, Aurora’s research into tie life prediction has advanced through expanded machine learning models trained on a dataset of over 100 million inspected ties. These models now incorporate a range of environmental and operational variables tied to the surrounding track environment. This allows for more accurate forecasting of tie degradation and remaining service life across diverse geographic and track conditions, Loram officials said.

By integrating predictive insights with durable, field-proven hardware, Aurora enables railroads to shift from reactive replacement strategies to proactive, data-driven maintenance planning, they said. Railroads can now prioritize tie programs based on actual condition and contextual risk, optimizing capital investments and extending the useful life of infrastructure, according to Loram.

Plasser American Corp.

Plasser American’s Ultrasonic Rail Flaw Detection system is designed as a continuous data collection system with post-processed analysis, as well as real-time display and defect monitoring.

Plasser American Corp.

Plasser American Corp.’s state-of-the-art Ultrasonic Rail Flaw Detection system is designed as a continuous data collection system with post-processed analysis, as well as real-time display and defect monitoring, company officials said.

The ultrasonic system can test at speeds up to 45 mph and maintain its pulse density by firing the transducers at a fixed 4 millimeter distance.

The system features enhanced pattern recognition with adaptive learning capabilities and can make real-time as well as post-processed decisions on suspect indications, Plasser officials said. The systems can be mounted on hi-rail trucks of different sizes or rail-bound cars.

Plasser offers an in-house line scan camera system and joint bar detection system that is compact enough to be installed on any of the company’s existing platforms. All of Plasser’s contracted hi-rails include the Ultrapass, the company’s walking stick with GPS and optional tablet with Plasser testing software.

Plasser’s workforce can perform both stop-and-verify and continuous testing, company officials said. Also, the company offers raw data analysis and verification services for existing Plasser or non-Plasser ultrasonic systems.

RailPod Inc.

Designed for daily use, RailPod’s platform collects detailed data on geometry, tie condition, rail profile, ballast, joint bars, fasteners and top-of-rail in one pass.

RailPod Inc.

As railroads work to improve safety, manage assets and control costs, RailPod Inc. provides a scalable and more cost-effective way to inspect track infrastructure, company officials said. Designed for daily use, RailPod’s platform collects detailed data on geometry, tie condition, rail profile, ballast, joint bars, fasteners and the top of rail in one pass.

The RailPod platform allows flexibility to inspect short lines, Class Is, transit systems and industrial tracks or yard environments. With minimal disruption to operations, railroads can inspect more frequently and make timely, data-driven maintenance decisions, RailPod officials said.

To support regulatory compliance, RailPod’s 213 Inspection App digitizes the manual inspection process, guiding users through each step, capturing data in the field and automatically generating ready-to-submit reports. It reduces paperwork and ensures accurate, consistent results, RailPod officials said.

Each inspection creates a “digital twin” of the right-of-way using high-resolution imagery, lidar, laser measurements and GPS data. This feeds directly into RailPod’s web and mobile software, giving customers instant access and tools for inspection, planning and engineering, company officials said.

RailPod continues to expand its capabilities with catenary wire measurements, broken rail detection, switch inspections, grooved rail measurements and restraining rail inspections.

RailPros

RailPros’ inspectors thoroughly evaluate the condition of all ties and switch components, rails (including joints and fasteners), ballast and drainage conditions.

RailPros

RailPros’ track inspection team conducts comprehensive railroad track assessments and Federal Railroad Administration (FRA)-required track inspections for Class Is, short lines, transit railroads and industrial track operators.

The company’s inspectors are FRA-qualified and trained to detect immediate issues and noncompliance, then recommend timely, cost-effective corrective actions, RailPros officials said.

When conducting an inspection, RailPros’ inspectors thoroughly evaluate the condition of all ties and switch components, rails (including joints and fasteners), ballast and drainage conditions to ensure compliance with federal and railroad safety standards.

RailPros also can help customers seeking to build new or redesign track.

RailWorks Corp.

RailWorks’ maintenance-of-way team combines advanced technology with experienced field personnel to deliver accurate, reliable data collection.

RailWorks Corp.

RailWorks Corp. offers a full spectrum of track maintenance and inspection services tailored to meet the diverse needs of the Class I, short-line and transit sectors across the United States and Canada.

RailWorks’ track geometry inspection programs are built on detailed baseline assessments and routine inspections, which are cornerstones for identifying potential issues and enabling proactive planning for long-term infrastructure integrity, company officials said.

RailWorks’ maintenance-of-way team combines advanced technology with experienced field personnel to deliver accurate, reliable data collection. The company’s fleet of inspection vehicles operate efficiently within tight track windows, capturing high-resolution data without disrupting operations, RailWorks officials said.

As the rail industry continues to evolve and embrace innovation, RailWorks is delivering actionable insights that help railroads manage increased volumes of data and translate them into meaningful improvements, they said. The company collaborates closely with clients to develop customized maintenance schedules that minimize downtime, prevent disruptions and optimize asset performance.

Senceive Ltd.

Senceive engineers developed a rockfall detection system for track sites that are vulnerable to blockage or damage caused by falling rocks and debris.

Senceive Ltd.

Many railroads in mountainous areas are vulnerable to rockfall events that can cause damage, disruptions and danger. That’s why engineers at Senceive Ltd. have developed a rockfall detection system designed for sites considered vulnerable to blockage or damage caused by falling rocks and debris.

The company’s responsive monitoring technology provides near real-time detection of sudden events, rapid alerts and high-quality photo verification for quick, actionable insights, Senceive officials said.

Unlike soil slopes, rock slopes are characterized by the unpredictable movement of individual boulders or localized debris, which a typical wireless slope monitoring system can miss when material falls between tilt sensor locations. This poses a significant threat to railroads, Senceive officials said.

By installing sensors on fences or barriers, events can be detected in three ways:

• rockfall by draw wire sensors, which detect gradual accumulation of material;
• impact detected by tilt sensors, which is ideal for detecting instantaneous events such as small- to medium-size boulders hitting the fence; and
• rotation of fence stakes detected by tilt sensors, which is the most reliable way to detect a large-scale rockfall that hits the fence with significant force.

An event detected by any of these three methods will trigger the system to accelerate reporting and send high-resolution site photos, Senceive officials said.

Built for rugged and remote locations, the wireless monitoring solution operates independently, requiring no external power or fixed communications infrastructure, they said.

Wabtec Corp.

Wabtec’s intelligent algorithms can precisely distinguish between critical and noncritical indications, which reduces false positives.

Wabtec Corp.

The rail inspection landscape is undergoing a transformative evolution, driven by increasing demands for safety, precision and operational efficiency. Wabtec Inspection Technologies is at the forefront of this revolution with its ultrasonic testing (UT) solutions that redefine rail flaw detection capabilities, company officials said.

Wabtec’s latest Rail Flaw Detection Systems address critical rail inspection challenges through innovative features. The system’s auto-alignment of roller search units ensures probe-positioning accuracy, minimizing human error and maximizing detection reliability, Wabtec officials said. The system automatically maintains optimal transducer angles, critical for consistent and comprehensive rail defect identification.

A key differentiator, they said, is Wabtec’s advanced run-on-run data comparison capability. By creating detailed historical inspection profiles, Wabtec’s system can detect subtle changes in rail conditions that might escape traditional inspection methods.

Enhanced AI-driven defect recognition represents another significant advancement. Wabtec’s intelligent algorithms now can better distinguish between critical and non-critical indications with remarkable precision, reducing false positives and allowing maintenance teams to prioritize interventions more effectively, company officials said.

The system can seamlessly transition between stop-and-verify and continuous testing modes using the same vehicle. This adaptability reduces operational complexity and provides comprehensive inspection capabilities without requiring multiple specialized vehicles, according to Wabtec.

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