Major overhauls of the railway superstructure

About the Company

Since 2010, Prombudkoliya has been performing major overhauls of the railway superstructure across Ukraine. We specialize in the rehabilitation of rail networks, sleepers, ballast, turnouts, and other track superstructure elements, extending track service life and improving train operation safety.

All works are carried out in accordance with Ukrzaliznytsia technical requirements, DBN regulations, and international standards. The company operates its own machinery fleet, production facilities, and a team of qualified specialists capable of executing projects of any complexity.

Purpose of Major Track Overhaul

Major overhaul of the railway superstructure is aimed at fully restoring the operational characteristics of a railway line. It eliminates wear, deformation, and defects accumulated over years of operation, ensuring compliance with modern requirements for load capacity, stability, and ride smoothness.

Scope of Work

Replacement of Rails and Sleepers

Dismantling of worn rails and sleepers followed by installation of new reinforced concrete sleepers of Types I and II, as well as rails R50, R65, and R75. Track panels are assembled, joint bars and fastenings are installed, and rail joints are adjusted.

Ballast Cleaning and Restoration

Removal of contaminated ballast layers, cleaning or complete replacement of ballast. New crushed stone ballast of 25–60 mm fraction is laid with layer-by-layer compaction, formation of the ballast prism, and installation of drainage systems.

Track Alignment and Stabilization

After component replacement, mechanized track alignment, tamping, and stabilization are performed. Machines such as VPO-3000, VPRS, and similar equipment are used to ensure accurate track geometry and gauge stability.

Turnout Overhaul

Major repair of turnout assemblies with replacement of frogs, stock rails, switch rails, under-rail plates, and switching mechanisms. Adjustment and testing are performed to ensure smooth vehicle passage and tight contact of elements.

Level Crossing and Deck Rehabilitation

Replacement of level crossing slabs, restoration of the crossing base, and installation of new rubber or reinforced concrete deck systems. When required, lighting and signaling systems are modernized.

Stages of Major Track Overhaul

1. Track condition diagnostics and inspection
2. Development of design and cost documentation
3. Dismantling of worn track superstructure elements
4. Ballast cleaning or replacement
5. Installation of sleepers, rails, and turnouts
6. Track alignment, tamping, and stabilization
7. Quality control and commissioning

Our Capabilities

• Major overhaul of railway lines of any length and category
• Works on mainline, industrial, and station tracks
• Modern machinery: VPO units, ballast hoppers, regulators, excavators
• Capability to perform works without complete traffic interruption
• Use of certified materials and track superstructure components
• Full technical supervision and project support

Company Advantages

• 15 years of experience in major railway track overhauls
• In-house production of sleepers, fastenings, and turnouts
• Mechanized execution with high precision
• Guaranteed quality and strict adherence to deadlines
• Proven track record of projects across Ukraine
• Certified specialists and an internal quality control department

Completed Project Examples

Major Overhaul of the Kyiv – Cherkasy Section (2023)

Replacement of sleepers and rails over a 7 km section, ballast restoration, track alignment, and stabilization. The project was completed within 60 days.

Industrial Track Rehabilitation at a Metallurgical Plant (Dnipropetrovsk Region, 2022)

Complete replacement of track superstructure elements and modernization of a turnout. Section throughput increased by 25%.

Major Overhaul of “Industrialna” Station (Kharkiv, 2021)

Reconstruction of six turnouts, track alignment and stabilization, drainage system upgrades, and level crossing rehabilitation.

Frequently Asked Questions

How often is a major track overhaul required?

The recommended interval is every 20–25 years of operation, depending on traffic intensity and ballast condition.

Is it possible to perform a major overhaul without stopping train traffic?

Yes. When required, works are performed in stages during scheduled maintenance windows, while maintaining traffic on adjacent tracks.

What warranty is provided for completed works?

A warranty of up to 5 years is provided for all types of major overhaul, subject to compliance with operational and maintenance regulations.

Request a Quotation

Need a major railway track overhaul? Submit a request, and Prombudkoliya specialists will conduct an inspection, prepare a project proposal, and offer the optimal technical solution for your site.