Automated Wagon Inspection Enables Predictive Freight Maintenance

GB Railfreight (GBRf) has entered into a ten-year maintenance agreement with Wabtec that introduces automated, data-driven inspection technology to the UK rail freight sector, aiming to improve wagon reliability, reduce in-service faults, and optimize lifecycle-based maintenance.

Transition to data-driven wagon maintenance
Under the agreement, maintenance of GBRf’s intermodal wagon fleet will be carried out at the GBRf Peterborough Maintenance Hub. The contract covers 585 FEA intermodal platform wagons and establishes a long-term framework for condition-based maintenance rather than traditional time- or mileage-based inspection cycles.

Central to the partnership is the deployment of Wabtec’s KinetiX inspection system, marking the first use of this technology in the UK rail freight market.

KinetiX inspection technology
KinetiX is a laser-guided, high-speed imaging system designed to inspect rolling stock at operational speeds. The system captures up to 20,000 images per second, generating high-resolution, data-rich records of wagon components during each pass through the inspection process.

This approach enables “pit-stop-style” inspections, allowing wagons to be assessed rapidly without extended downtime. The imaging data provides precise visibility of component condition, wear patterns, and emerging defects that may not be detectable through conventional visual inspections.

Lifecycle-based maintenance strategy
By combining KinetiX inspection data with lifecycle analytics, GBRf and Wabtec will shift to a proactive maintenance regime. Wagons will be assessed based on their actual condition and calculated remaining service life, rather than fixed inspection intervals.

This model is intended to reduce in-service failures, improve fleet resilience, and support higher availability of wagons for intermodal operations. Early identification of defects also enables targeted interventions, helping to avoid secondary damage and unplanned withdrawals from service.

Operational and network impact
The introduction of automated inspection and predictive maintenance is expected to improve maintenance efficiency and consistency across GBRf’s intermodal fleet. Faster inspections reduce time spent in maintenance facilities, while data-driven decision-making supports more accurate planning of component replacement and overhaul activities.

For the wider rail network, improved wagon reliability contributes to more stable freight operations, fewer service disruptions, and better utilization of maintenance resources.

Strategic context
The agreement reflects a broader shift within the rail freight sector toward digitalization and predictive asset management. Automated inspection technologies such as KinetiX align with industry efforts to increase efficiency, improve safety, and reduce whole-life costs through better use of data.

By committing to a ten-year partnership, GBRf and Wabtec establish a long-term platform for continuous improvement in wagon maintenance practices, positioning the Peterborough Maintenance Hub as a reference site for advanced freight wagon servicing in the UK.

Application perspective
For freight operators managing large wagon fleets, the ability to assess asset condition at speed and with high precision is becoming a key differentiator. The GBRf–Wabtec collaboration illustrates how automated inspection and lifecycle analytics can be integrated into day-to-day operations to support higher reliability and more predictable maintenance outcomes.

As rail freight volumes and customer expectations continue to grow, such technologies are likely to play an increasing role in modernizing wagon maintenance across the sector.