From rust to revival

...Inside Zambia Railways’ $20 million journey to rebuild its future DOREEN NAWA, Kabwe THE rhythmic sounds of grinding metal, welding sparks illuminating workshop corners and engineers huddled around locomotive components are becoming symbols of a quiet transformation underway in Kabwe. For years, Zambia’s railway sector has grappled with ageing rolling stock, reduced locomotive availability and increasing dependence on hired equipment to meet growing freight demands. The challenges have weighed heavily on Zambia Railways Limited (ZRL), limiting operational efficiency at a time when regional trade and industrial activity continue to expand. Yet amid those struggles, conversations around repositioning rail as a driver of economic growth had begun gaining momentum. In 2025, during the Land- Linked Zambia Conference, stakeholders emphasised the need for Zambia to leverage its strategic geographic position to transition from being merely landlocked to becoming a land-linked regional logistics hub. Central to that vision was a functioning and efficient railway system capable of supporting industrialisation, reducing transport costs and facilitating regional trade. And ZRL managing director Cuthbert Malindi took it personal and engaged with possible partners.

He imagined a full functional rail system that will soon be a centre of excellence for not only the Southern African Development Community (SADC) but Africa as a whole. Just over a year later, that ambition is increasingly taking shape on the workshop floor at Zambia Railways Main Workshops in Kabwe. The US$20 million strategic partnership signed in February 2026 between Zambia Railways Limited and Worldwide Rail and Mining Solutions (WWRMS) for the rehabilitation and modernisation of six GT 3600HP mainline locomotives is no longer confined to boardroom discussions and signed agreements. It is visible. Three months after commencement of works, the workshops in Kabwe have become a hive of activity. During a media tour of the ongoing rehabilitation programme, teams of engineers and technicians worked methodically to dismantle worn-out components, assess structural integrity and rebuild locomotive systems designed to restore performance and extend operational lifespan. The atmosphere reflects urgency, but also optimism. A total of 45 personnel are directly involved in the rehabilitation programme, comprising 35 Zambia Railways employees working alongside 10 specialists from Worldwide Rail and Mining Solutions. The interaction between local and international teams underscores one of the project’s most important objectives – its technical skills transfer. For Worldwide Rail Technical lead Shadrack Qotso, the rehabilitation programme is about creating sustainable engineering capacity alongside restoring locomotives. “We are committed to ensuring that these locomotives are restored to high operational standards through quality workmanship and rigorous technical processes. Equally important is ensuring that the knowledge remains with Zambia Railways through practical training and collaboration with local engineers,” Mr Qotso said during the workshop tour. He explained that the project is designed to deliver long-term operational reliability while strengthening local technical expertise. “Our approach is not simply to complete the rehabilitation works and leave. We want Zambia Railways engineers to gain practical exposure throughout the process so that the institution strengthens its internal maintenance capabilities,” he said. The emphasis on local capacity development resonates strongly with Zambia Railways officials overseeing the project. For ZRL project lead Kavimbi Chipusu, a senior engineer, the progress recorded within three months has brought renewed confidence. Walking through sections of the workshop where locomotives are undergoing refurbishment, Mr Chipusu reflected on the significance of the programme. “This project gives us hope because we are seeing practical skills development and measurable progress on the rehabilitation works. The involvement of ZRL engineers throughout the process means the expertise gained will strengthen our capacity to maintain and manage these locomotives going forward,” he said. He noted that beyond increasing locomotive availability, the rehabilitation programme is rebuilding technical confidence within the institution. “There is optimism among staff because this initiative demonstrates investment in our people, infrastructure and future operations. The knowledge transfer taking place will benefit Zambia Railways long after the rehabilitation project is completed,” Mr Chipusu added. The six GT 3600HP locomotives undergoing rehabilitation form part of broader efforts by Zambia Railways to address persistent locomotive shortages that have affected freight operations in recent years. Limited availability of locomotives has forced the company to depend significantly on hired equipment, increasing operational costs and exposing services to disruptions amid rising demand for freight movement. The ongoing rehabilitation programme aims to reverse that trend. Implemented through a vendor- financed deferred payment structure, the arrangement allows rehabilitation works to proceed without requiring substantial upfront capital expenditure from Zambia Railways. Repayment toward the US$20 million investment will instead be made over time using revenues generated from operations by the refurbished locomotives. The phased programme will see the first two locomotives deployed between May and June 2026, followed by another two in August and the final pair before the end of the year. For the ZRL managing director, the initiative represents more than equipment restoration. “This partnership represents a major step in rebuilding Zambia Railways’ operational capacity. By rehabilitating our own locomotives, we are not only restoring critical national assets but also improving reliability, increasing freight volumes and reducing reliance on hired locomotives,” Mr Malindi said. He believes the completed rehabilitation programme will significantly increase haulage capacity and improve service delivery to sectors including mining, agriculture, manufacturing and energy. The broader implications extend far beyond Zambia Railways itself. Historically, railway systems have played a defining role in industrial development worldwide. Efficient freight movement lowers production costs, improves supply chain reliability and facilitates large- scale movement of raw materials and finished products. Rail remains particularly important for bulky commodities. A single freight train has the potential to transport cargo equivalent to approximately 50 trucks. For economies reliant on mining and agriculture, this creates substantial cost savings while reducing pressure on road infrastructure. In Zambia, commodities such as copper, fertiliser, fuel, cement and agricultural produce depend heavily on efficient transport systems. Strengthening railway capacity could therefore contribute significantly towards improving competitiveness across multiple industries. Reduced dependence on road transport also offers environmental and economic benefits through lower fuel consumption, reduced emissions and decreased road maintenance costs. As Africa advances implementation of the African Continental Free Trade Area (AfCFTA), efficient transport systems are becoming increasingly critical. The AfCFTA seeks to create a single African market and boost intra-African trade by reducing barriers between countries. However, expanded trade opportunities require strong supporting infrastructure. Countries with efficient rail networks are likely to gain competitive advantages in regional logistics and manufacturing. For Zambia, centrally positioned within southern Africa and bordering eight countries, revitalised rail infrastructure presents an opportunity to strengthen trade corridors and improve connectivity to regional ports and markets. The vision of Zambia becoming a land-linked logistics hub depends heavily on transport efficiency. That is why the rehabilitation works taking place in Kabwe carry significance beyond the workshop floor. At the signing of the agreement in February, Worldwide Rail and Mining Solutions managing director Jason Visagie said restoring the locomotives means supporting broader economic ambitions. “The rehabilitation process will involve a comprehensive rebuild and upgrade of the locomotives to ensure they meet modern operational requirements. Our goal is to deliver high-quality engineering solutions that will extend the service life of these locomotives while enhancing their operational efficiency,” he said. He added that collaboration with Zambia Railways engineers remains central to ensuring sustainable outcomes. Inside the Kabwe workshops, the signs of transformation are increasingly difficult to ignore. Where ageing locomotives once symbolised operational decline, they now represent renewal.

Teams move between workstations with purpose. Components are rebuilt. Skills are exchanged. Institutional confidence is slowly being restored. The transformation underway is not merely mechanical. It is organisational. It is economic. And perhaps most importantly, it is symbolic of what strategic investment, partnerships and long-term vision can achieve. What began as discussions during Land-Linked Zambia 2025 is increasingly becoming visible progress. For Zambia Railways, the journey from operational challenges towards renewal is no longer an aspiration waiting on the horizon. It is unfolding in real time inside the busy workshops of Kabwe. It’s one rebuilt locomotive, one trained engineer, and one restored opportunity at a time. The whistle signalling departure may soon carry a deeper meaning. Not simply the movement of trains. But the movement of a railway company — and perhaps a nation’s logistics ambitions — from rust to revival.