In June this year, we learned how Affective Rail and Plant’s innovative Track Remover and Carrier System or TRACS is making work sites safer and more efficient with its ability to move prefabricated track panels with minimal on-site assembly.
The innovative machine, designed in-house, operates with precision control and dramatically improves installation timelines – from days to mere hours.
The TRACS Alpha, as the first iteration is called, includes integrated lifting systems, an adjustable lifting beam, and full remote control for safe placement of panels.
It has proven a success in turnout removal and installation for a range of networks and mainline operations requiring heavy-duty handling capabilities.
But not all networks or projects have the real estate to allow for large plant like the Alpha variant, which has prompted Affective Rail and Plant to develop a brand-new model.
The TRACS Bravo variant delivers the same performance and safety benefits as the Alpha – in a smaller, more versatile package.
Affective’s Director of Specialised Plant, Billy Jordan, said the company has received lots of positive feedback from rail operators and contractors using the TRACS Alpha so far – as well as several requests for the TRACS range to be expanded.
“Customers have highlighted how much they valued reduced track possession times and improved worker safety, as well as having the ability to build new turnout panels where they have enough real estate to do so and bring them onto track where they traditionally wouldn’t be able to in these locations,” he said. “At the same time, some customers operating on narrower or more constrained networks told us they needed a smaller machine that could deliver the same benefits.
“That input directly influenced the Bravo’s size, design, and transportability.”
Jordan said the Bravo is ideal for narrow gauge systems such as those in regional Queensland or Perth in Western Australia, where prebuild of large panels can’t always be constructed next to the install point.
“It also suits urban or industrial settings with tight access points, tunnels, or yards where traditional equipment is too large to manoeuvre effectively,” he added.
It’s not the first time that Affective has innovated to fill a gap in the Australian rail market – this is also how the Alpha version of the TRACS machine came to be.
“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,” Jordan 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, track-guided unit capable of delivering and placing turnout sections safely and quickly.”
From there, the team prototyped, field-tested, and refined the TRACS machine in close consultation with end-users, putting real-world functionality first.
“We ensured it not only met engineering benchmarks but delivered genuine on-site value,” Jordan said.
The Alpha model was designed to accommodate long turnout bearers of up to 6.5 metres in length, while the Bravo handles bearers measuring up to 5.3 metres long.
Apart from size and track gauge adaptability, the key difference is transportability, with the Bravo’s compact frame allowing easier mobilisation between sites.
Crews can build turnout sections beside the install point and side shift them into position, or track them in from a nearby location, without the need to have track sections to run on.
While the Bravo is smaller and lighter than the Alpha, it maintains the same lifting capacity per machine as its predecessor.
The Bravo, like all TRACS machines, uses Affective Rail and Plant’s patented centre lift technique.
This design greatly reduces the risk of overturning compared to conventional cranes or excavator-type machines, making lifting operations far more stable.
“In addition, operators control the machine remotely rather than being seated inside it, so in the unlikely event of a failure, no one is near the suspended load,” Jordan added.
“Together, these features significantly lower the risk of accidents on site.”
Minimising the need for workers near moving loads not only boosts safety, but can reduce costs and simplify site logistics, particularly on busy or remote networks.
A suite of complementary accessories and attachments are also available for all TRACS machines, including adjustable hydraulic H beams, for handling different turnout geometries.
Jordan said Affective Rail and Plant always tries to provide a complete system, not just a standalone product.
“This ensures our clients can integrate the equipment into their workflows smoothly and efficiently,” he said.
The machines are designed and purpose-built in Australia, to suit the unique requirements of the environment and customers’ project demands. This reduces modification costs and ensures full compliance.
Affective consults closely with field crews and project teams during development to address specific pain points, particularly around manual handling, transport logistics, and speed of installation.
Currently, a prominent Australian operator is using the Alpha TRACS model for turnout installations on a major project.
“Early feedback has been extremely positive, especially around safety improvements and reduced installation times,” said Jordan. “We expect the Bravo will soon be trialled on some of their narrow-gauge lines to deliver the same benefits in tighter settings.”
Jordan also expects rapid uptake of the Bravo among other operators of narrow-gauge networks in Queensland, mining companies, and regional rail authorities.
“Urban transit networks with restricted work sites are also likely to see immediate benefits,” he continued.
Affective Rail and Plant is gearing up to officially launch the Bravo at AusRAIL PLUS in Melbourne from November 25–28, 2025.
“AusRAIL is the premier rail event in the region, so unveiling the Bravo there puts it in front of the entire industry,” said Jordan.
“It’s a major opportunity to showcase how TRACS technology is evolving to meet diverse rail network needs.”
Jordan said the release of the Bravo won’t affect the popularity of the Alpha as they are complementary models.
“Many projects may ultimately require a combination of both for maximum flexibility,” he said. “Together, the Alpha and Bravo offer an efficient solution for modern turnout installations across a range of railway settings.”
Looking to the future, Jordan has big plans for the business.
“We’re exploring models optimised for different track conditions, transport methods, and even full integration with digital worksite planning tools to further streamline installation and maintenance processes. The Alpha and Bravo are just the beginning.”
