Integrated Infrastructure Solutions for Modern Urban Rail Networks

Managing growing passenger numbers and shorter train intervals requires resilient, low-maintenance infrastructure components in urban mass transit systems. By combining specially developed sleepers and flexible point operating systems, a technical solution is provided for metro networks with severely restricted space constraints.

Challenges in Urban Rail Transport
Subway networks worldwide are experiencing increasing utilization, leading to condensed timetables and correspondingly smaller time windows for maintenance work. To meet these infrastructural challenges, voestalpine Railway Systems develops integrated system solutions designed for high reliability and minimized maintenance. The focus is on slab tracks and turnout systems that are mechanically and functionally coordinated to facilitate system integration and reduce interfaces during installation.




Technical System Solution and Functionality
The technical implementation is based on the integration of the ESS25 sleeper system and the zentrak UNISTAR HR point operating system. The sleeper system features structured side surfaces with integrated nubs. This design enables direct interlocking with the surrounding cast-in-place concrete of the slab track. This eliminates the need for additional components such as brackets or lattice girders, measurably reducing the steel requirements in the construction. The prestressed design minimizes the risk of cracking during handling and installation. Furthermore, the sleepers can be manufactured using CEM-III concrete mixtures.

The hydraulic point operating system has a modular design and achieves an IP68 protection rating. A central hydraulic unit can supply up to four actuation levels, allowing different system concepts to be realized. The reduced system weight simplifies installation, while continuous condition monitoring is integrated into the system to support condition-based maintenance strategies and minimize unplanned interventions.




Implementation and Application Areas
The combined system is primarily designed for metro projects in narrow tunnels and densely built-up urban areas. The point operating system offers flexible installation concepts and can be positioned either centrally in the track or variably alongside it. This enables integration into various track and superstructure designs, even in highly space-constrained environments. Prefabricated mounting points in the concrete sleepers allow for the direct and rapid installation of the point machine. An integrated manual override function additionally helps to minimize time and personnel requirements in the event of potential system faults.




Presentation at the Trade Fair
voestalpine Railway Systems will present these technical developments and system integrations at InnoTrans, the international trade fair for transport technology, taking place from September 22 to 25, 2026, at the Berlin exhibition grounds.

Edited by Maria Brueva, Induportals Editor – adapted by AI.

www.voestalpine.com