EU rail network of the future: Benchmarking study for condition-based maintenance as the key to efficiency and cost-effectiveness
Maintenance of rail infrastructure has always been, and remains, critically important for ensuring good network condition . However, with the current emphasis on expansion projects and the constraints of tight budgets, maintenance often gets sidelined. To shed more light on this challenge, civity conducted a deep dive study to explore various methods of assessing network conditions and their link to a more preventive approach to maintenance and renewal (M&R). As part of the PRIME benchmarking group formed by the European Commission Europe-wide infrastructure managers (IM) provided detailed insights for the conduction of this study. The study reveals the key learnings and approaches to assess network condition which enables a long-term oriented M&R strategy.
It was found that Network Condition Reports (NCR) are considered a valuable strategic management tool, which most European Rail Infrastructure Managers (IM) started to produce over the last decade. This improves the reporting on of asset condition and therefore deepens the understanding of it. M&R as well as funding needs are clarified and enable a holistic view on network condition.
NCRs usually mention the underlying causal link between M&R and network condition. However, linkages between specific maintenance activities and resulting network condition are, so far, rarely pointed out. It seems difficult to depict such cause-effect relations in a short-term perspective with asset data quality and availability being a key challenge for IM.
In line with the goal of increasing knowledge on asset condition, IM seek to develop and refine their M&R strategy. This allows them to reduce corrective activities and move towards a more preventive and condition-based M&R approach. Currently the two main sources of information used to create M&R strategy are the theoretical Life Cycle Cost (LCC) modelling and the condition-based inspection of assets. IM strive to combine both types of condition data and use calculated theoretical lifetime with current inspection insights. With this the expected remaining lifetime of the assets can be assessed in an iterative process. Accurate remaining lifetime data allows to determine frequency and timing of inspections better. Increased knowledge also permits for maintenance and renewal works being adapted to the actual asset condition.
M&R expenditures average at about 40% of total expenditures for IM, which is substantial. Deferring planned M&R activities due to budgetary reasons does usually not lead directly to a loss of quality in the short term, however spotlights from the study show that in the longer term an increase in overall rail infrastructure spending is often caused.
Safety is always a given, and IM’s M&R strategies focus on meeting this base requirement. However, few go further to also focus on sustaining the assets optimal lifetime and optimising lifecycle costs.
In three spotlights the study highlights that from a long-term perspective, budgetary reasons seem to speak in favour of an M&R strategy that focuses on sustainable asset conditions. A reduction of M&R activities to only failure repairs guarantees safety but backfires with a time lag. In the medium to long term the total cost of maintenance often exceeds the initial savings, the service quality deteriorates and the need for earlier renewal pushes up expenses even more. A detailed description of these spotlights is available in the official study summary.
However, the need for long-term maintenance and renewal planning and investment also highlights the conflict of interests that railway infrastructure managers often face. There is a discrepancy between short-term savings opportunities in M&R and economically sustainable, long-term efficient and high-performance operation of the railway infrastructure. Last but not least, the current deplorable condition of the railway infrastructure in Germany makes it impressively clear how important it is to resist the temptation of short-term savings.