Mainmark is extending its proven expertise in non-invasive ground engineering to one of infrastructure’s most complex, demanding and exciting sectors: rail.

“The rail sector is deeply traditional and highly regulated. You can’t just roll in with a clever solution and expect instant buy-in,” he explains. “But when people see what we can do and how fast, with a competitive cost base, we usually get a call back for repeat business.”

That capability lies in Mainmark’s innovative ground improvement, re-levelling and void filling technologies, including Teretek® and Terefil®.

These solutions deliver rapid, measurable results in hours rather than weeks, often without shutting down the line, a major advantage for a sector balancing growing demand, restrictive maintenance budgets, and climate-driven challenges.

Already proven in road and aviation, Mainmark’s solutions are now helping rail operators extend asset life, reduce disruption, and improve safety, all while working within the sector’s strict operational constraints.

Smarter maintenance without disruption

Rail networks are designed to endure constant vibration and heavy loading across the passenger and freight tracks. Over time, this causes movement that can affect ride quality and safety, which can result in speed restrictions or unplanned renewals.

Traditionally, when this happens, asset renewals (eg track, structures) have to be undertaken, and this has been costly and disruptive.

Mainmark offers an alternative. Its fast-curing, highly controlled materials allow maintenance crews to mobilise, stabilise, and complete works overnight within standard short possessions or occupations, or in some cases, works can be completed during normal train running under strict safety protocols.

“It’s value for money in every sense,” McTaggart says. “You’re not tearing up infrastructure. You’re not halting services. And you’re extending asset life.”

The surprising speed of change

For many asset managers and maintainers, Mainmark’s speed is eye-opening.

“One client told us, ‘I didn’t know you could just drill small-diameter holes, inject resin, and solve a track slab void overnight,” McTaggart recalls.

The key is adopting a more sustainable approach. We want to show our colleagues in rail maintenance that there’s another way forward, one that fits their requirements and enhances, rather than disrupts, their operations.

Recent technical roundtables with operators and maintainers across Australia and the UK have showcased these results, with site inspections often booked the following week.

Built for live rail environments

Mainmark’s products are designed to meet the demands of high-traffic networks. Teretek expands to fill voids and stabilise weak ground, while Terefil is ideal for abandoned culverts, inaccessible voids, and challenging geotechnical conditions. Both can be applied within short maintenance windows, sometimes in just a few hours.

The company recognises the importance of rigorous railway planning: product approvals, risk assessments, site-specific designs, and compliance with rail safety accreditation are all part of the process, and with each rail network in Australia having its own safety accreditation requirements, that planning becomes even more critical.

“We work hand-in-hand with clients from inspections to geotech surveys, through to final design and delivery,” McTaggart explains. “We bring engineering rigour and safety compliance to every project.

“As part of our commitment to client partnerships, we always follow up with our clients to see how the asset is performing. Our ongoing monitoring programs are designed to validate performance and demonstrate the continued success of our engineered solutions.”

Resilience in a changing climate

The need for smarter maintenance is growing as funding shifts from the recent major infrastructure investment over the past 10 years to existing and ongoing asset management. Climate volatility is adding further pressure, with flooding, heat, and erosion threatening all railway systems, but more so on regional and remote networks.

Mainmark doesn’t aim to replace large-scale renewals but instead focuses on critical weak points before they fail. By integrating survey and rectification data into digital asset management systems, the company also helps rail owners plan more effectively, extending renewal cycles and prioritising funding.

“We can tell them what was injected, how deep, how it performed and help them project how long it’s likely to last. That’s data they can use to justify extending asset life and push out renewal cycles to prioritise funding,” McTaggart says.

The challenge of visibility

Despite global success across Australia, New Zealand, Japan, and the UK, McTaggart admits Mainmark is still building presence and recognition in rail. The company is tackling this by engaging at industry events, rail forums, and direct client meetings.

“People might think of us as a small operator,” he says. “But once they see our international footprint, they understand our scale and capability.

“We believe there is a gap in the market for our rail service and look forward to being part of the railway family and working collaboratively together and proactively supporting the asset planning process. If we’re in the room partnering and collaborating, we can save time, money and future issues through these key risk mitigation strategies that we have been delivering in other sectors for years.”

Looking ahead

When asked what’s next, McTaggart hints at some future directions, including resin-based ballast stabilisation, already proven overseas and updated formulations that reduce embodied carbon and set even faster to meet sustainability targets.

But McTaggart says the real focus is on relationships: “It’s about engaging early, helping asset managers plan, respectful challenge, and showing that asset preservation doesn’t have to mean disruption or delay.”

At AusRAIL 2025, Mainmark staff will be in attendance all week, building connections and listening to industry needs.

“It’s not just about selling solutions,” McTaggart says. “It’s about engagement, collaborating, offering up solutions and helping rail operators and maintainers keep assets safe, reliable, available, maintainable and resilient.”