Rack railways have made it possible to run trains in steep and mountainous areas, by offering better traction and stability. This paper takes a closer look at the design challenges and practical solutions involved in upgrading these systems – especially when moving from traditional fish-plated jointed tracks to continuously welded rails in embedded track configurations. The authors focused on the forces acting on the rack, how thermal expansion is handled and what happens where tracks meet bridges. Using analytical methods and Finite Element Analysis (FEM), this work examines how different loads and temperatures affect the rack’s performance, especially in tight curves and high-gradient areas. The findings highlight the importance of flexible support structures, strong anchorage, and the use of durable rail profiles like TN70. The study also underscores how small design tweaks – like adjusting geometry or material properties – can go a long way in boosting both performance and lifespan. Overall, this work contributes to building safer, longer-lasting rack railway systems, that are easier to maintain over time.