Behind Railway Journeys: Innovations in Eco-Friendly Track Maintenance
Every train journey that carries passengers to various destinations involves a long process to ensure that the tracks remain in good condition. Behind these journeys, various infrastructure maintenance innovations are being continuously developed by KAI through the use of increasingly modern materials and technology.
PT Kereta Api Indonesia (Persero) continues to develop infrastructure maintenance through the utilisation of synthetic sleepers as well as the use of battery-based and electric maintenance equipment. This step is part of KAI’s efforts to maintain track quality, increase field work efficiency, and support better environmental management.
KAI Vice President of Corporate Communication, Anne Purba, stated that safe and comfortable train journeys are supported by the readiness of various aspects, including the infrastructure upon which the trains move.
“Behind the train journeys enjoyed by customers, there is a continuous maintenance process. Kally continues to introduce innovations in maintenance materials and technology so that infrastructure remains reliable and supports environmental sustainability,” said Anne.
One of the innovations implemented by KAI is the use of synthetic sleepers made of Fibre Reinforced Foamed Urethane as an alternative material for rail sleepers. This material has a longer technical lifespan compared to wooden sleepers and possesses better resistance to weather and environmental conditions.
The use of synthetic sleepers has continued to grow in recent years. According to KAI data, the procurement of synthetic sleepers was recorded at 5,656 units in 2022, increasing to 16,353 units in 2023, then 15,864 units in 2024, 13,789 units in 2025, and 16,839 units in 2026. Overall, throughout the 2022–2026 period, KAI has procured a total of 68,501 synthetic sleepers.
Anne explained that the use of synthetic sleepers supports the track maintenance process because they have greater durability. This material helps reduce the frequency of material replacement, reduces the use of wood as a raw material, and supports the reduction of waste generated from material replacement.
To ensure material quality before use, synthetic sleepers undergo various technical tests. These tests include flexural strength and Young’s modulus tests, flexural load resistance, longitudinal compressive strength, shear strength, adhesive shear strength, current penetration voltage, insulation resistance, screw spike pull-out strength, dimensional measurement, fire resistance, fatigue resistance, and weather resistance.
In addition to using new materials on the tracks, KAI is also transforming infrastructure maintenance equipment through the use of battery-based and electric technology. Cordless equipment is being utilised to support maintenance work to make it more efficient and provide greater ease for field officers.
Currently, several battery-based tools used by KAI include impact wrenches, drills, lighting, grinders, and track geometry trolleys. These tools support various maintenance activities, ranging from the installation of track components, drilling work, area lighting, material cutting, to track geometry measurement.
KAI is also preparing to expand the use of battery-based equipment through procurement plans for various devices, such as battery rail saws, rail grinders, electric hydraulic jacks, battery-powered portable tampers, battery drills, electric paint sprayers, electric high-pressure washers, and chain saws. The use of such equipment supports maintenance work that is more practical, ergonomic, and efficient.
The transformation of infrastructure maintenance equipment towards battery and electric technology is part of KAI’s steps to reduce the use of fuel-based equipment and support more environmentally friendly maintenance operations.
In addition to developing maintenance technology, KAI also carries out various environmental management programmes at infrastructure facilities. These programmes include the implementation of Wastewater Treatment Plants (IPAL) to ensure liquid waste from washing and maintenance activities meets quality standards before being released into the environment, hazardous waste (B3) management in accordance with regulations, and routine environmental audits in work areas.
KAI is also preparing plans to install Solar Power Plants (PLTS) at the Balai Yasa Prasarana through the installation of photovoltaic solar panels to support operational electricity needs. This step is accompanied by the implementation of energy efficiency and green building concepts in infrastructure maintenance facilities.
Anne added that innovation in infrastructure is part of KAI’s journey to provide railway services that are increasingly ready to meet public needs.
“Train journeys begin with well-maintained tracks. Through innovations in materials, maintenance technology, and environmental management, KAI continues to maintain the quality of infrastructure so that passenger journeys become increasingly safe, comfortable, and reliable,” Anne concluded.