Switches are at the heart of every rail network. They determine direction changes, cycle accuracy and safety during operation. But what happens if a fault occurs at precisely this point? A defective switch can quickly become a critical point – with massive consequences: Delays, train cancellations, detour, special train services and, in the worst case, even derailments.
The increasing demands on availability and punctuality in rail transport make one thing clear: repairs to switches must not remain a reactive emergency – they must be part of an intelligent maintenance strategy. What is needed are robust systems, modular components and digitally supported processes that not only rectify faults, but at best prevent them.
Bharat Forge CDP Railsystems meets these challenges with a clear claim: reliability through innovation. With low-maintenance switch locking systems, resilient frogs and sophisticated overall solutions for railroad infrastructure, we provide answers to the pressing questions of modern turnout maintenance.
What is a turnout – structure, function, meaning
Switches are one of the most important components of railroad infrastructure. They enable trains to change direction and move from one track to another – and are therefore essential for flexible and efficient rail traffic.
Basic principle and function
In technical terms, a turnout is a track element that connects two tracks. It consists of several precisely coordinated assemblies:
- Tongue device: movable rail sections that determine the direction of the train
- Centerpiece: central area where the routes intersect – heavily loaded by the passing of bicycles
- Stock rails: guide the wheels through the switch area
- Locking and drive system: ensures that the tongues are securely positioned and fixed in place
- Monitoring devices: provide feedback on the current position to the signal box
Relevance for the company
Every turnout is a safety-critical element. Their malfunction can lead to significant operational disruptions – in the worst case, to a derailment. In addition, the punctuality of the entire train service often depends on just a few points, especially in busy areas such as main stations or on single-track sections of line.
Switch types at a glance
- Single turnout
Standard form for switching between two tracks with a branch in one direction. - Double crossover (DKW)
Complex design that enables both crossing and branching movements – often in confined station areas or with space-saving track layouts. - Internal points
Technical term for turnouts with switches that are located between the rail heads – regardless of where they are used. Often necessary for tight radii or special track guidance.
In practice, the choice of switch type is decisive:
- Operational safety
- Maintenance effort
- Compatibility with control and monitoring systems
Components such as the centerpiece or the fasteners are subject to particular stress – and are the focus of repair and maintenance.
Find out more about “What is a turnout?” and how it is constructed in these articles:
Why is the repair to the turnout so critical?
While many technical components in rail transportation can forgive a temporary malfunction, this is often not the case with switches. An incorrectly functioning turnout represents a considerable safety risk. Repairing the points is therefore not only necessary, but urgent – with far-reaching consequences for operations, infrastructure and passengers.
Safety risks in the event of a malfunction
An incorrectly positioned or damaged switch can cause a train to travel in the wrong direction – or, in the worst case, derail. This is particularly critical at high speeds, for example on long-distance or express services. This is why particularly strict maintenance and inspection regulations apply to switches.
Effects on the operating process
- Delays: Even a short-term blockage of a switch can affect dozens of trains.
- Detour and timetable disruptions: Particularly on lines with tight headways – such as the S3 towards Berlin – switch disruptions quickly lead to a domino effect.
- Rail replacement service (SEV): In the event of longer cancellations, buses must be organized, passengers informed and replacement plans activated.
- High coordination effort: control centers, maintenance teams, train drivers, DB Netz – everyone has to work in parallel to rectify the disruption.
Critical locations – maximum impact
Some points are particularly sensitive to operation:
- Intersection areas in large cities (e.g. Berlin, Munich)
- Approaches to main stations with high train density
- Track switching points on single-track lines in rural areas
Here, the condition of a single turnout determines the performance of the entire network.
Publicity and economic consequences
A switch failure is more than just a technical problem – it affects public confidence in the railroads. Repeated failures can damage the image and cause costs running into millions.
Causes and effects of switch malfunctions
The switch – an inconspicuous but complex system of mechanical, electrical and control components. It is precisely this complexity that makes them particularly susceptible to faults. The causes are as varied as the places where they are used:
Mechanical wear and material fatigue
Daily operation exerts enormous forces on switch blades, frogs, locks and drives. The frog of the switch, where wheels meet with high energy, is subject to particularly high loads. Without regular maintenance, cracks, chipping or deformation can occur there – with a direct impact on driving safety.
Electrical and control errors
In modern interlockings, signals, sensors and actuators control the movement of the points. Defective cables, faulty feedback signals or faults in the signal box quickly lead to incorrect positions – and in extreme cases to operational downtimes.
Weather and foreign bodies
Leaves in the fall, ice in the winter, softened ballast beds in the summer – nature plays its part. Added to this are foreign objects in the track area, such as tool debris, garbage or larger objects. They block tongues and drives, lead to emergency shutdowns or unnoticed misalignments.
Consequences for the company
The “classic” disruption case: a train reports a points fault. The line is closed, the train crew must continue by order, replacement services are organized. The consequences:
- Delays and cancellations
- Risk of derailment in the event of undetected failure
- Cost-intensive repairs
- Loss of image towards passengers and clients
Particularly in highly frequented areas – such as intersections, exits of large stations or changeover areas on lines such as the S3 towards Berlin – such disruptions can paralyze the entire regular service.
The repair process in detail – step by step
The repair of a turnout is not a standardized routine process. However, it follows clear technical procedures that ensure that operational safety, efficiency and documentation are guaranteed at all times. Whether an acute case of damage or a planned measure – the repair is divided into several phases.
1. fault detection and initial notification
It all starts with something conspicuous:
- The train driver notices a misalignment or is unable to drive over the points.
- Automatic systems in the interlocking detect deviations in the actuation process.
- An error message is triggered and forwarded via the operational communication system.
Typical signals:
- No feedback from the point machine
- Noticeable switching noise
- Standstill during the changeover
- Deviations in “distance-time behavior”
2. securing and closing the route section
Safety has top priority:
- The affected section of track will be closed to train traffic.
- Signals show “Stop” and the train crew receives instructions to continue or to stop.
- If necessary, an emergency manager is called in – especially at busy junctions.
3. visual inspection and initial diagnosis
A qualified maintenance team is sent on site:
- Visual inspection for obvious damage (e.g. broken tongue, loose parts)
- Checking the locking mechanism and the frog
- Detection of the type of fault: mechanical, electrical or control-related
Mobile diagnostic tools are often used here, for example:
- Current measurement during switching operation
- Temperature measurement of the servomotors
- Querying error codes from the control unit
4. repair intervention
The type of repair depends on the fault pattern. Possible measures:
- Mechanical interventions: Replacement or readjustment of reeds, closures, springs or frog components
- Electrical work: Replacement of servomotor, cables, sensors
- Software interventions: resetting the control unit, reparameterization
Note:
Thanks to the modular systems from CDP Railsystems, many components (e.g. turnout locks) can be replaced or adapted with minimal effort – without time-consuming dismantling.
5. functional test
A comprehensive examination is carried out after the procedure:
- Switch is set several times (preferably with a test train)
- Feedback signals are evaluated
- Mechanical components are visually inspected again
- Restoration is documented directly in digital form or in the maintenance log
6. re-release and tracking
After a successful check, the section is released again:
- The signal box is informed
- The traffic controller lifts the closure
- The measure is documented in the system (incl. time, team, spare parts)
Depending on the specifications, a follow-up check is carried out after 24-72 hours in order to detect possible consequential damage or readjustments at an early stage.
Special challenges during repairs
Switch repairs rarely take place under ideal conditions. In reality, every measure is a balancing act between safety, speed and the operational environment. The demands on people, materials and methods increase, especially in complex track sections or extreme weather conditions.
Switches in highly frequented junctions
The intervals between trains are often short at stations such as Berlin Central Station or at transfer hubs such as the S3 line. A blocked switch can lead to a backlog of connections within minutes – with consequences for the entire route.
Special features:
- Short maintenance windows (often at night between 1:00-4:00 a.m.)
- Restricted access to components (e.g. in the case of covered track systems)
- Increased coordination effort with operations management and security service
Crossing and track change areas
In these areas, several points are located close to each other and are sometimes mechanically or electrically coupled. A repair can therefore also block other routes – with additional interventions in the operating sequence.
Exemplary challenges:
- Several switches must be secured at the same time
- Incorrect feedback can overlap each other
- Risk of chain faults due to faulty interference suppression
Repair under extreme conditions
Winter operation: Ice and snow get stuck in tongues, drives and frogs. If a technical fault occurs at the same time, a quick repair can be made more difficult or delayed.
Summer heat: Strong expansion of metallic components changes the actuating behavior. Electronic components overheat or switch off.
Autumn and leaves: Slippery gravel or damp leaves not only disrupt driving operations, but also make access and the safe execution of work more difficult.
Darkness & night work: Poor visibility, reduced working time windows, noise restrictions – all of these increase the risk of errors and extend the repair time.
Safety and occupational safety
Repairs in the track area are subject to strict regulations. Work groups must be secured, paths must be kept clear and electrical fuses must be observed. CDP Railsystems takes these requirements into account when developing its products – for example through simple assembly processes, integrated grip zones and low-wear components that require less maintenance.
Strategies for effective switch repair
Repairing the turnout is much more than simply replacing defective parts. It is an integral part of a strategic maintenance concept – with the aim of rectifying faults quickly and preventing them in the long term.
Quick fault diagnosis as a basis
It is crucial to localize and classify the fault precisely – ideally before a failure occurs. Modern sensor technology, as integrated in digital interlockings and drive units, provides important data here: from temperature curves and switching times to feedback errors. The rapid evaluation of this information makes it possible to react in a targeted manner and with minimal downtime.
Availability of critical spare parts
Time is the most important factor in repairs. Delays often occur because special components – such as locking components or frogs – are not immediately available. CDP Railsystems therefore relies on a modular system architecture and enables efficient stocking and interchangeability thanks to standardized components.
Example: Our point locks are designed to be quickly installed and compatible with existing systems – this significantly reduces downtimes in the event of a malfunction.
Deployment of specialized maintenance teams
Repairs to the switch are safety-relevant – they may only be carried out by qualified specialists. CDP Railsystems works with certified technicians who not only have technical excellence, but are also trained in dealing with time pressure, parallel traffic and safety regulations.
Communication in the event of an incident
In an emergency, the interaction between train crews, signal boxes and maintenance also counts. Clear chains of command and digital tools such as mobile maintenance apps improve the speed of response – and prevent subsequent problems such as faulty journeys or derailments.
Innovative solutions from Bharat Forge CDP Railsystems
Efficiency, safety and availability – these three requirements are at the heart of modern rail infrastructure. CDP Railsystems meets the challenges of switch maintenance with highly developed products that are specifically tailored to these requirements.
Low-maintenance point locks
Switch locks are safety-critical – they reliably fix the switch position. CDP Railsystems develops standardized, highly compatible systems with a focus on low maintenance:
- Current closure types: WKV, BFL, EVZ
- Advantages of the ECC system:
- New development on behalf of Deutsche Bahn
- Replacement of older shutter generations without conversion
- Automatic length compensation function of ± 35 mm (e.g. in the event of temperature fluctuations)
- Contribution to system harmonization and reduction of variants
EVH frog lock – reliable and low-maintenance
The centerpiece is a particularly stressed zone of the turnout: This is where forces from different directions converge – including high axle loads, lateral forces and impact loads from the wheel.
For moving frogs, Bharat Forge CDP Railsystems supplies the EVH frog lock – a proven system for reliable and durable fixing of this sensitive component.
Advantages of the EVH system:
- Robust design for secure locking function in the centerpiece area
- Modular design for easy maintenance and replacement
- Significant reduction in maintenance costs thanks to durable materials
The EVH belongs to the latest generation of low-maintenance turnout locks – developed for high operational reliability and long-term cost-effectiveness in rail operations.
The EVZ Toolkit – working efficiently on the switch
For precise and safe work on turnout locks, Bharat Forge CDP Railsystems offers the EVZ Toolkit – a specialized tool system consisting of two practical cases.
- Installation case: with all tools for professional installation
- Maintenance case: for targeted maintenance measures
The EVZ Toolkit has been specially developed to facilitate installation and maintenance work on turnout systems. It consists of 2 cases with an individual weight of 12 kg and 13 kg. A case contains the complete equipment for maintenance work on switch locks. A second case complements the range with the necessary tools for a complete assembly. This means that the tools are neatly separated and the entire equipment does not have to be transported for maintenance work.
System integration and modularity
Another advantage of the CDP approach: all components are coordinated with each other. This not only makes maintenance easier, but also reduces the complexity of repairs. Whether it’s the centerpiece, fastener or attachment – everything is designed for consistent system logic.
Long-term partnership and individual solutions
CDP Railsystems sees itself not only as a supplier, but also as a partner to operators. From engineering and training to maintenance planning, we offer modular services – tailored to the type of route, traffic volume and operational requirements.
You can find out more about how we see ourselves and our innovative strength on the Bharat Forge CDP Railsystems company page.
Maintenance and digitalization – developments at a glance
Traditional maintenance of turnouts is currently usually interval-based – i.e. according to fixed schedules or mileage values. However, current projects show that the industry is moving towards predictive maintenance, also known as “preventive” or “condition-based” maintenance.
Bharat Forge CDP Railsystems is following these developments closely and is contributing its expertise in areas where standardized, reliable maintenance of locking systems is required – for example with the EVZ Toolkit, which supports technicians in carrying out professional maintenance on site.
Current status: Intervals instead of status data
At present, the maintenance of our products such as the EVH frog closure or classic closure systems is still based on fixed maintenance intervals. Sensor integration for recording temperature, current consumption or vibrations is not currently planned.
Perspective: Support through clear documentation
The aim is to make work on the switch easier through modular product concepts and maintenance-friendly design. In addition, CDP Railsystems provides support with technical documentation, installation documents and training courses – compiled on a project-specific basis if required.
Advantages for operators
- Fewer malfunctions and failures
- Targeted planning of maintenance windows
- Lower life cycle costs
- Higher availability of the route
For example, preventive measures can significantly improve punctuality on a highly frequented line such as the S3 towards Berlin – a clear advantage for operators and passengers.
Conclusion & outlook: Rethinking turnout repair
Repairing a switch is more than just a technical intervention – it is a central component for the reliability of the entire rail transport system. Whether a mechanical defect, electrical malfunction or software failure: every switch malfunction has a direct impact on safety, punctuality and network stability.
Bharat Forge CDP Railsystems meets these requirements with a practical approach for robust, maintenance-friendly products. The focus is on:
- Reliable locking systems such as the EVH for moving frogs
- Modular, standardized components that enable fast repairs
- Tool solutions such as the EVZ Toolkit – for efficient maintenance and assembly processes
The future of switch maintenance is networked, predictive and fully documented. Operators who rely on predictive systems not only ensure smoother operations – they also increase customer satisfaction and reduce their costs in the long term.
You can find out more about our solutions for modern rail infrastructure on our company pageWould you like to take your maintenance to the next level?
Talk to us – we will be happy to advise you.