Rolling stock modernisation – giving old trains a new lease of life .

Faced with rising costs for new rolling stock, tight investment budgets and increasingly stringent environmental requirements, rail operators are increasingly opting to modernise their existing rolling stock. Thanks to modern technologies and advanced design tools, it is now possible to refresh decades-old designs in a way that meets the realities of the 21st century – at a significantly lower cost than purchasing new vehicles. 

In this article, we discuss: 

• what is rolling stock modernisation,
• why modernisation may be a better alternative to purchasing a new vehicle, 
• what are the benefits of rolling stock modernisation, 
• what are the challenges associated with modernisation, 
• how does the train modernisation process work, 
• current trends in rolling stock modernisation. 

What is rolling stock modernisation? 

Rolling stock modernisation is more than just repair – it is a comprehensive overhaul of a railway vehicle that goes beyond mere restoration to improve and expand its functionality, safety, comfort and compliance with current standards. It includes, among other things, the reconstruction of the vehicle’s front end, the modernisation of the driver’s cab, new cladding materials (e.g. aluminium, composites), as well as changes to the interior – from the seating layout to air conditioning, passenger information and Wi-Fi systems. The drive, electrical and safety systems are also often upgraded to ensure that the vehicle meets the most important current TSI, EN and fire safety standards. The result? Longer service life, better energy efficiency and rolling stock adapted to modern expectations. 

Modernisation instead of purchase 

Rolling stock modernisation is a viable alternative to purchasing new vehicles. It allows existing units to be upgraded at 30% to 50% of the price of a new train, reducing the delivery time to about a dozen months. This is particularly cost-effective when the basic structure of the vehicle, i.e. the frame, load-bearing elements and mechanical components, remains in good condition. The modernisation process usually covers areas such as the drive system, driver’s cab, passenger interior, on-board installations and safety systems. It is estimated that it can extend the service life of a vehicle by up to 15 to 20 years.

The benefits of rolling stock modernisation are multifaceted. They include lower investment costs, simplified vehicle approval, improved energy efficiency (e.g. thanks to new drives and LED lighting) and significantly increased passenger comfort. What is more, modernised rolling stock also improves safety. This is due to, among other things, the installation of advanced monitoring systems, better protection of the driver’s cab in the event of collisions and compliance with current fire safety requirements. 

Technical challenges in rolling stock modernisation 

Rolling stock modernisation is not just about changing the appearance or installing new systems. It is also a complex technical process that requires the precise adaptation of new solutions to the existing vehicle structure. The key challenges of rolling stock modernisation are: 

• adapting the new front end to the existing structure – it must ensure full structural and aerodynamic compatibility with the rest of the vehicle, while meeting collision standards (e.g. EN 15227) and allowing for the installation of modern systems (cameras, sensors, radars). 
• integrating new systems with existing infrastructure – ETCS, monitoring, HVAC and passenger information systems must be integrated into often outdated electrical and mechanical systems without compromising their functionality. 
• design constraints – factors such as available technical space, total vehicle weight, axle load distribution and the geometric parameters of the bogie, base frame and car body must be taken into account.
• compliance with standards and certification – each modernised vehicle must comply with a number of current regulations, including TSI LOC&PAS and PRM, as well as EN standards for fire safety and electrical installations. 
• assessment of material fatigue – before modernisation, a thorough analysis of the technical condition of the structure is necessary, including non-destructive testing. This allows the economic and technical feasibility of modernisation to be assessed. 

Modernisation offers great opportunities, but it has its own specific characteristics and requires precision, experience and a skilful combination of modernity and the limitations of the existing platform. 

How does the modernisation process work? 

Rolling stock modernisation is a multi-stage process that requires precise planning, engineering know-how and close cooperation between design, technology and production teams. It consists of several stages: 

1. technical audit – a thorough analysis of the technical condition of the vehicle: from the base frame and load-bearing elements, through the bogies, to the electrical installations and cabin equipment. At this stage, components that need to be replaced, repaired or adapted to standards are identified.
2. design and computational simulations – a key stage of any modernisation. The process begins with applying the planned changes to a 3D model, followed by virtual CAE validation, which includes, among other things, strength analyses (FEM) and crash tests in accordance with EN 15227. Simulations allow us to assess the rigidity of the structure, the distribution of crumple zones and the level of safety in the driver’s cab even before production begins. The course of this process can be seen in our case study (example project): ‘Optimisation of the structure of the type 20D locomotive’. 
3. production and prefabrication of components – new components, such as the vehicle front, side wall elements and interior modules, are manufactured in accordance with technical documentation at a modernisation plant. Functional and safety tests are also carried out there. 
4. assembly, testing and certification – Prefabrication is followed by component assembly and system integration. The final stage consists of operational tests, approvals and acceptance by the customer.

Trends in modernisation 

The modernisation of rolling stock is a dynamic process that evolves with technological developments and growing market requirements. We are currently observing several key trends: 

• hybrid modernisation – classic bodywork supplemented with a lightweight composite vehicle front. This solution improves aerodynamics, safety and aesthetics while maintaining the original’s robustness. This is clearly visible in our project ‘Modernisation of the front structure of the ED72 electric multiple unit’. 
• smart systems – advanced monitoring and management systems are becoming standard. The installation of external cameras, sensors, radars and intelligent systems allows for better control of the vehicle’s surroundings, obstacle detection and even assistance to the driver with automatic braking systems. This is also an important step towards full integration with traffic control systems such as ETCS. 
• recycling and reuse of materials – sustainable development activities are gaining importance. Recycled materials are increasingly being used in the modernisation process, as well as technologies that enable the recovery and reuse of large rolling stock components, such as base frame. This not only reduces costs, but also reduces the carbon footprint of vehicle production and modernisation.
• environmental and social requirements – vehicles must be accessible to people with reduced mobility, which requires, among other things, special ramps, wider aisles and interior amenities. In addition, improving acoustic comfort is important – quieter interiors improve passenger comfort, and better thermal insulation increases the comfort and energy efficiency of the vehicle, reducing energy consumption for heating and air conditioning. 

Development through modernisation 

Today, rolling stock modernisation is not only a way to extend the life of vehicles, but above all a tool for building modern, safe and competitive rail transport in a shorter time. It allows for the incorporation of current technical standards, increased passenger comfort, reduced energy consumption and shorter vehicle implementation times, while significantly reducing costs compared to the purchase of new units. 

Modernisation is therefore not just a technical refresh of the vehicle, but a well-thought-out, strategic investment that allows for a flexible and economical response to market needs and improves the image of the carrier without the need to replace the entire fleet. 

At Endego, we support rolling stock manufacturers in a wide range of rail vehicle design and optimisation services, from the front-end modernisation and strength analyses to the integration of modern systems and preparation of certification documentation. 

📩 Contact us to discuss your project.