Keeping People Safe and Projects Running Smoothly
The mobility revolution is well underway, and we no longer raise the question of whether something needs to happen but face the challenge of how to best realize it.
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With a rise in population, networks are quickly becoming more complex and denser, schedules are tighter and many of the existing network components are reaching their end of life meaning there is a growing need for replacements.
The increase in maintenance combined with the more frequented lines lead to less room for downtime, more time pressure and a surge in potential errors. It is our goal at ZÖLLNER to make sure that everyone who works on or along the tracks gets home safely.
Different Construction Sites, One Warning System
Track construction sites come in many forms—ranging from rural to urban environments, from compact zones to expansive multi-mile projects, and from routine surveying tasks to complex operations like full track renewals. To meet these diverse demands, we developed a warning system that is both highly flexible and easily scalable: the ZÖLLNER Mobile Radio Warning System (MRWS).
While every warning system follows the same basic principle – detecting an approaching train, processing the signal in a control unit, and alerting workers via warning devices – our MRWS stands out for its modularity. The adaptability of the system makes for solutions that are tailored to the specific conditions of each worksite.
To ensure maximum flexibility, the system’s configuration can be tailored to the specific conditions of each site. Train detectors can be mounted quickly using a magnetic clasp, streamlining setup on the tracks. In complex environments with multiple tracks—such as station approaches—train detection can also be performed by a lookout using a hand-held radio transmitter. If used in hand-held modus, the transmitter ensures reliable warnings via the vigilance control which needs to be triggered frequently by the lookout. Should there be no active response by the lookout, the system immediately triggers a warning, thus preparing a save state at the worksite. The control unit processes incoming signals and activates all connected warning devices, such as the ZPW126-10, ensuring timely and reliable alerts for trackside personnel.
The allrounder ZPW126-10 warns people exactly where they are working
The ZPW126-10, the latest addition to the MRWS family, was developed in compliance with CENELEC standards and meets the stringent requirements of SIL4, meaning that it is a failsafe warning system with the highest possible safety integrity level defined in functional safety (according to standards such as IEC 61508/CENELEC) which sets the most rigorous requirements for a system’s safety and reliability standards.
Its optical and acoustic components are housed in a robust, weather-resistant casing designed for maximum practicality: up to 24 units can be stacked on a single Euro pallet, significantly reducing transport costs and logistics effort.
Equipped with wireless, plug-in batteries, the ZPW126-10 simplifies battery management and saves valuable time on site. Batteries can be replaced during ongoing operation, ensuring uninterrupted functionality. Thanks to the continuous Autoprowa® effect, the warning signal automatically adjusts itself between 97 dB(A) and 126 dB(A), allowing optimal adaptation to ambient noise levels. 360° visibility is ensured by LEDs positioned on every corner of the device.
Additionally, the ZPW126-10 can serve as a receiver to trigger machine-based warning systems via the ERRI interface. Using its magnetic holder, it can be mounted directly onto construction machinery or excavators—allowing the warning signal to move with the equipment and remain aligned with the source of noise.
Offering Efficiency and New Opportunities
The ZÖLLNER warning system is designed to do two things exceptionally well: protect people and boost efficiency on track construction sites. Its failsafe technology ensures reliable alerts for approaching trains—minimizing downtime and allowing work to continue without unnecessary interruptions.
Built on state-of-the-art technology, the system offers personnel new qualifications that change their work environment for good. It is built to support and enhance their work, helping them maintain the highest level of safety for the teams they protect.
How the ZÖLLNER MRWS can make Worksites Safer in Canada Immediately
In line with national regulations and infrastructure company standards, the Mobile Radio Warning System (MRWS) can be deployed alongside existing processes to deliver maximum safety. Errors remain a significant risk in railway operations, particularly as multiple people are involved in securing a worksite before a train can pass. By installing a track sensor directly behind the flag that signals a train to stop and await clearance, lives can be saved
Once the train passes the flag, the sensor detects it and the radio transmitter relays the information to the control unit. The system then issues a warning signal across all connected devices. Because large numbers of warning devices can be integrated, each group under a subforeman is equipped with a collective warning unit that alerts all workers of an approaching train. If communication protocols have been followed, the signal sounds as the worksite is already cleared. However, if a breakdown occurs anywhere in the communication chain, the MRWS prevents a potentially fatal situation.
Beyond accident prevention, the system creates a safer and more focused work environment. Workers can rely on a dependable warning independent of human action, allowing them to concentrate fully on their tasks. This not only improves safety but also enhances efficiency in right‑of‑way operations.
Designed for resilience, the MRWS has been tested and deployed under challenging conditions—including hilly terrain, dense urban areas, tunnels, and near large structures—and has proven reliable even where other radio communication methods may fail.
Built to last, the MRWS represents a cost‑effective investment with rapid return. Our mission is to support customers into the future by continuously improving and advancing our existing safety solutions.
Safer Worksites around the World
Our systems have been successfully deployed in over 12 different countries across the globe on the tracks of major infrastructure companies such as Deutsche Bahn, Network Rail, Systra, RFI, Infrabel, and Sydney Trains. In order to best serve our customers’ needs, we have also partnered with some of these companies to make tailored adjustments to our technology.
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