Increased availability in the smallest spaces: voestalpine Railway Systems presents integrated system solution at InnoTrans 2026

2026-08-19 |

Metro networks worldwide are facing ever-increasing demands: passenger numbers are rising, trains are running at shorter intervals, and maintenance work must be carried out within increasingly tight timeframes. At InnoTrans 2026, voestalpine Railway Systems will demonstrate how a modern, low-maintenance infrastructure can meet these challenges with its ESS25 embedded sleeper system and the zentrak UNISTAR HR point setting system. As a perfectly coordinated system solution, both products combine high reliability, flexible installation options, and ease of installation.

Innovative sleeper system: Fewer components, easier installation

With the ESS25, voestalpine Railway Systems presents an innovative sleeper system for slab track and turnouts. The sleeper's unique feature is its specially designed side surfaces with integrated studs. These ensure optimal interlocking with the surrounding cast-in-place concrete, resulting in a particularly strong bond.

This eliminates the need for additional components such as stirrups or lattice girders on the side surfaces. This not only simplifies the design but also facilitates transport and installation. At the same time, the prestressed construction ensures high resistance and reduces the risk of cracking during handling, transport, and installation.

The sleeper can also be manufactured using a more environmentally friendly CEM-III concrete mix.

Advantages compared to other systems:

Reduced steel requirements, as lattice girders are not required.
Optimal embedding in the cast-in-place concrete slab of the slab track.
Improved interlocking with the surrounding concrete due to the structured side surface.

Learn more about ESS25

zentrak UNISTAR HR: Flexible, robust, and low-maintenance

The zentrak UNISTAR HR point setting system was specifically developed for demanding operating conditions. Its modular design allows for flexible integration into a wide variety of infrastructure concepts, making the system particularly attractive for metro projects with limited space.

The drive units can be positioned both inside and outside the track area, while a central hydraulic unit can supply multiple control levels. This enables the efficient implementation of even complex systems.

Another advantage lies in its high reliability. The system has proven itself worldwide under a wide range of climatic conditions – from snow and frost to hot desert regions. This is complemented by modern condition monitoring solutions that support condition-based maintenance and can reduce unplanned interventions.

The advantages at a glance:

Flexible installation options for the drive unit, either centrally located in the track or variably positioned next to the track. Ideal for projects with limited space.
Central hydraulic unit for up to four control levels enables different system concepts and easy integration into various track and superstructure designs.
Easy integration into existing infrastructure thanks to reduced interfaces to the interlocking system.
High reliability and stable operation thanks to robust construction and high resistance (protection class IP68).
Continuous condition monitoring with zentrak SWITCH CONDITION MONITORING as the basis for condition-based maintenance.
Reduced system weight for easier installation with less equipment required.
User-friendly manual operation significantly reduces time and personnel costs in the event of a malfunction.

Learn more about zentrak UNISTAR HR

Stronger together: An integrated system solution

The ESS25 sleeper system and zentrak UNISTAR HR were designed to work together seamlessly from the outset. Pre-installed mounting points in the concrete sleeper enable quick installation of the switch drive. At the same time, operators benefit from a single-source system solution that reduces interfaces and simplifies installation.

This combination offers a reliable and maintenance-friendly solution, particularly for metro projects in narrow tunnels, densely populated urban areas, and other challenging infrastructure environments.

With this integrated system solution, voestalpine Railway Systems will present a vision at InnoTrans 2026 of how the metro infrastructure of tomorrow can be designed to be efficient, robust, and sustainable.

The two systems are perfectly coordinated, can be installed efficiently, and reduce the number of interfaces within the project. This creates the foundation for a reliable and low-maintenance infrastructure that meets the increasing demands of modern metro networks.

The InnoTrans is regarded as THE most important international trade fair for transportation technology and takes place every two years at the Berlin Exhibition Grounds. To mark its 30th anniversary, voestalpine Railway Systems — the world’s leading provider of complete railway infrastructure systems — will showcase its latest developments in digital system solutions.

Come visit us!

Experience System Performance on Track® from September 22–25 in Hall 21b, Booth No. 150.