Technological Excellence in Turnout Systems: Insights from Our System Experts

2025-10-27 |

Turnouts are far more than mechanical junctions—they are high-load, integrated subsystems that play a decisive role in the performance, safety, and maintainability of railway infrastructure. In our latest interview series, five system experts from voestalpine Railway Systems provide insights into the development of customized turnout systems for Mixed Traffic, Metro, Tram, Freight, and High-Speed applications.

Mixed Traffic – Turnout technology as a versatile performer

Sven Rinder knows mixed traffic like few others. With over 30 years at voestalpine, he describes the unique challenges of this complex segment:

Turnouts must accommodate everything — from slow regional trains to high-speed and heavy freight. We rely on reinforced components, harder rail grades, and optimized fastening systems to create a resilient overall system.

Digital twins and condition-based monitoring enable predictive maintenance:

Our system approach reduces interfaces and ensures smooth coordination—from the rail to diagnostics.

Read the full interview here

Metro – Availability in high-frequency networks

For Robert Demal, Vice President Product Management Fixations and a recognized system expert in metro systems, one thing is clear: system availability is key.

Metro lines have no redundancy. A single failure has immediate consequences. Our pre-assembled, function-tested systems are designed for fast installation and minimal maintenance.

Integration with signaling and diagnostic systems ensures synchronized operation:

We deliver a complete system—not individual components. This reduces coordination effort and increases service life.

Read the full interview here

Tram – Tailored solutions for urban complexity

With over 40 years of industry experience, Thomas Christ knows the specifics of tram systems. As Head of Business Center Tram and system expert, he emphasizes their unique requirements:

Each city has its own demands. We develop prototypes tailored to tight spaces and specific wear patterns.

Materials are selected for high reparability and wear resistance:

The digitalized turnout detects issues early and enables targeted maintenance—without time-consuming inspections.

Read the full interview here

Freight – Highest quality for maximum loads

Brent Duffner has been part of voestalpine for over two decades. As a system expert for heavy haul, he understands the extreme stresses these systems endure — and why every detail matters:

Freight turnouts must withstand extreme axle loads. Our systems are robustly engineered and equipped with digital monitoring to reduce lifecycle costs.

Digital systems provide real-time diagnostics and prioritize maintenance actions:

They enhance operational safety and reduce unplanned interventions.

Read the full interview here

High-Speed – Precision at 360 km/h and beyond

Burkhard Zillien brings over 30 years of railway experience. As a system expert for high-speed applications, he knows the challenges in detail—and highlights the complexity of this demanding segment:

Changing tracks safely at 230 km/h requires a 200-meter turnout. We develop systems that combine safety, speed, and cost-efficiency.

Digital feedback from operations flows directly into product development:

We optimize materials and components based on real-world performance data—for longer service life and reduced wear.

Read the full interview here

System thinking, lifecycle optimization, and digital integration

voestalpine Railway Systems applies a holistic engineering approach: mechanical robustness meets digital intelligence. From RAMS optimization and predictive maintenance to customer-specific development—each turnout system is precisely tailored to operational and infrastructure requirements.