Affective Rail and Plant is a privately-owned rail and project delivery contractor in Australia, delivering cost-effective solutions across a broad spectrum of projects.
The business specialises in designing and manufacturing bespoke rail maintenance machines, tailored to Australian conditions and client needs.
Billy Jordan, Head of Business Development and Specialised Plant, said its most notable innovation is its TRACS (Track Remover and Carrier System) machine.
“Purpose-built for the safe and efficient transport and installation of large turnout sections, the TRACS machine is capable of moving prefabricated track panels with minimal on-site assembly, allowing for swift and precise installation,” he said.
“The machine includes integrated lifting systems, an adjustable lifting beam, and full remote control for safe placement of panels.
“It operates with precision control and can install a full turnout in significantly less time than traditional manual or semi-mechanical methods, especially where there are tight access constraints.”
Another key product is Affective Rail and Plant’s 15-tonne Ballast Boxes, which are designed to simplify and streamline the distribution of ballast material during renewals and maintenance.
“These units are engineered for rapid deployment and easy handling, with rugged construction to handle demanding rail environments,” said Anthony Stewart, Chief Executive Officer of Affective Rail and Plant.
The design process
Jordan said the design process for Affective Rail and Plant’s products always starts with observation.
“Many of us at Affective Rail and Plant come from operational or project delivery backgrounds, so we’ve experienced first-hand the inefficiencies and safety risks of traditional methods,” he said.
“In the case of the TRACS machine, we saw that turnout installation was labour-intensive, time-consuming, and heavily reliant on large cranes.
“That sparked the idea of a self-contained, rail-guided unit capable of delivering and placing turnout sections safely and quickly.”
From that point, Affective Rail and Plant prototyped, field-tested, and refined the TRACS machine in close consultation with end-users.
“We ensured it not only met engineering benchmarks but delivered genuine on-site value,” Jordan said.
“Our project-focused engineering puts real-world functionality first.”
A purpose-built product
All Affective Rail and Plant’s TRACS machines are designed and built locally in Australia, to suit the unique requirements of the country’s rail networks and project demands.
“Our business model is built on being responsive to project challenges, not just supplying machines,” said Jordan.
“Because our machines are purpose-built, this minimises modification costs and ensures full compliance, unlike some imported systems that require adaptation to Australian standards.
“Innovation is core to our approach – we consult closely with field crews and project teams during development to address specific pain points, particularly around manual handling, transport logistics, and speed of installation.”
The TRACS machines also offer flexibility for the client to build the turnout sections beside the install point and side shift them into position, or alternatively track them in from a nearby location, without the need to have track sections to run on.
Saving time
Jordan said the TRACS machine also stands out due to its ability to handle full-size turnout panels, reducing the need for on-site fabrication.
“It dramatically improves installation timelines, from days to mere hours,” he said.
“This not only minimises possession windows and service disruptions but also reduces the need for multiple shifts, heavy cranage, and large on-site teams.”
Likewise, Affective Rail and Plant’s Ballast Boxes reduce the frequency of refilling runs, streamline the process of ballast spreading, and enhance worksite efficiency.
“These time savings translate directly to reduced project costs, better resource management, and safer working conditions,” said Stewart.
“Every hour saved during track work is critical – our machines help maximise that value.”
A suite of accessories
Affective Rail and Plant has also developed a suite of complementary accessories and attachments that expand the capabilities of its machines.
“For the TRACS machine, we offer adjustable hydraulic H beams, for handling different turnout geometries,” Jordan said.
“We always aim to provide a complete system, not just a standalone product.
“This ensures our clients can integrate the equipment into their workflows smoothly and efficiently.”
Tried and tested
The TRACS machine has been used on multiple projects, including high-profile turnout replacements.
“The Australian Rail Track Corporation has used the TRACS machine for building rail infrastructure, in cases where possession windows were extremely limited,” said Stewart. “The feedback has been overwhelmingly positive, particularly around how the machine improves safety and reduces installation time.
“Operators have noted the precision and ease of use, while project managers appreciate the cost and time savings.”
Jordan said there is a strong appetite for the machines in Australia.
“With the growing focus on asset reliability, project delivery efficiency, and workforce safety, rail operators and contractors are actively seeking smarter tools,” he said.
“Clients are no longer content with outdated machinery, they want equipment that can do more with less. That’s exactly where our machines come in. We’re seeing growing demand not just for machines, but for our collaborative design approach.”
Affective Rail and Plant has also had expressions of interest from international operators and Jordan sees strong potential for expansion, especially in regions where track renewal demands are increasing, and labour efficiency is under scrutiny.
Jordan said: “We have also partnered with a distributor in the United States to help bring these solutions and centre lift method to North and South America.
“Affective Rail and Plant continues to lead the way in modern rail maintenance solutions by designing machines that work smarter, faster, and safer.”
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