KAI Develops Greener Rail Maintenance with Innovative Materials and Technology

Behind every train journey is a continuous maintenance process to keep railway infrastructure reliable. KAI continues to develop its infrastructure maintenance practices by introducing new materials and technologies, from synthetic sleepers to battery and electric powered equipment, while strengthening environmental management across its infrastructure facilities.

PT Kereta Api Indonesia (Persero) continues to improve infrastructure maintenance through the use of modern materials and technology. The developments are aimed at maintaining track quality, improving the efficiency of fieldwork, and supporting more environmentally friendly operations.

VP of Corporate Communication KAI Anne Purba explained that safe and comfortable train journeys depend on reliable railway infrastructure. KAI therefore continues to develop maintenance materials and technology to ensure that the infrastructure remains reliable while supporting environmental sustainability.

One of the developments is the use of Fiber Reinforced Foamed Urethane synthetic sleepers as an alternative to wooden sleepers. The material has a longer service life and better resistance to weather and environmental conditions.

The use of synthetic sleepers has continued to grow in recent years. KAI recorded the procurement of 5,656 synthetic sleepers in 2022, 16,353 in 2023, 15,864 in 2024, 13,789 in 2025, and 16,839 in 2026. In total, KAI procured 68,501 synthetic sleepers from 2022 to 2026.

Their longer service life also brings benefits to track maintenance. Anne explained that synthetic sleepers can reduce the frequency of material replacement, lower the use of wood as a raw material, and help reduce waste generated from replacing sleepers.

Before being used, the synthetic sleepers undergo a series of technical tests to ensure their quality. These include tests for flexural strength and Young’s modulus, flexural load resistance, longitudinal compressive strength, shear strength, adhesive shear strength, dielectric strength, insulation resistance, screw spike pull-out strength, dimensional measurements, fire resistance, fatigue resistance, and weather resistance.

The shift toward more efficient maintenance also extends to the equipment used by field personnel. KAI has started using cordless equipment powered by batteries and electricity to support various infrastructure maintenance activities.

The equipment currently used includes impact wrenches, drills, lighting equipment, grinders, and track geometry trolleys. These tools support tasks ranging from track component installation and drilling to work-area lighting, material cutting, and track geometry measurement.

KAI is preparing to expand this approach through the planned procurement of 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 equipment is expected to make infrastructure maintenance more practical, ergonomic, and efficient while reducing the use of fuel-powered equipment.

Environmental management is another part of KAI’s infrastructure maintenance practices. At its infrastructure facilities, KAI applies wastewater treatment plants to ensure that liquid waste from washing and maintenance activities meets applicable quality standards before being discharged. KAI also manages hazardous and toxic waste in accordance with regulations and conducts regular environmental audits in work areas.

KAI is further preparing to install a solar power plant (PLTS) at the Infrastructure Maintenance Workshop, using photovoltaic panels to support operational electricity needs. The plan is complemented by energy-efficiency measures and the implementation of green building concepts at infrastructure maintenance facilities.

Anne added that the development of maintenance materials, technology, and environmental management is part of KAI’s efforts to keep its infrastructure ready to support growing public mobility needs. With well-maintained infrastructure and more environmentally friendly maintenance practices, KAI continues to support safe, comfortable, and reliable train journeys.