INNOTRANS 2026 - EXHIBIT

Prefabricated turnout slab – a tailor-made solution

CONTRACK technology was developed as a flexible system of large-size prefabricated reinforced-concrete slabs that can be individually adapted to the technical standards applicable in different cities and tramway systems.

The turnout slab presented here has been designed with regard to the standards of the Verband Deutscher Verkehrsunternehmen (VDV) for the steel turnout component. The presented R=50 m turnout has been manufactured using a shallow trough design with low switch blades and internal-chamber heating. This type of construction is successfully used in many German cities. It demonstrates that CONTRACK is not limited to a single type of design – the geometry of the prefabricated slab, steelwork, fastening system and equipment can all be designed in accordance with the requirements of a specific operator and project.

This is the essence of tailor-made prefabrication: the benefits of industrial production combined with the ability to individually design infrastructure for each city.

CONTRACK. One slab. Any surface. Prefabrication adapted to the city.

Prefabrication does not have to mean a uniform concrete surface. Large-size CONTRACK slabs can be manufactured with different types of surface finishes, adapted to the character of the urban space and the requirements of a specific project.

The slab surface can feature an individually selected concrete texture – including brushed or mould-patterned finishes – or can be integrated with paving blocks, other surfacing materials or a green track system.

The exhibited element combines a paving-block surface with a green track solution, demonstrating the broad technological and architectural possibilities of the system. This makes it possible to combine the speed and quality of prefabrication with the aesthetics of urban spaces and solutions supporting the development of green infrastructure.

The exhibited prefabricated slab incorporates the most popular and most widely used R=50 m turnout design on the Polish market. It is a turnout manufactured using a deep trough design with high, replaceable switch blades and external heating boxes located outside the stock rails.

TWO-LEVEL EXHIBIT

PREFABRICATED SLAB WITH COMPENSATING DEVICE

CONTRACK extends the possibilities of large-size prefabrication for tramway infrastructure to applications requiring expansion devices.

The solution integrates the track surface and an expansion device into a single prefabricated element, allowing the compensation of rail movements resulting, among other things, from temperature changes.

One of the joints of the presented expansion device is made of 60R2 rails and allows the stock rail and switch blade to move relative to each other by 100 mm (±50 mm travel). The rails are embedded in an ERS resilient continuous fastening system using Sika Icosit KC 340(50)/50 materials.

Transferring such a complex infrastructure component to a prefabricated solution enables the structure to be prepared under controlled production conditions while reducing the scope of work carried out directly on site.

PREFABRICATED LEVEL CROSSING SLAB 60E1

Experience gained through the design and implementation of large-size prefabricated slabs for tramway infrastructure has provided the basis for developing CONTRACK technology for railway applications.

The presented element is a large-size prefabricated slab integrated with a 60E1 railway rail, designed for heavily loaded level crossings with high road traffic volumes.

The use of large, individually designed prefabricated elements makes it possible to reduce the number of components and joints within the crossing and to transfer a significant part of the construction process from the site to controlled production conditions. The concept was developed with the aim of increasing structural durability while reducing installation time and future maintenance requirements.

This represents another stage in the development of CONTRACK – from tramway prefabrication to large-size prefabrication for railway infrastructure.

PREFABRICATED CRANE RUNWAY SLAB S100

The CONTRACK technology of large-size prefabricated elements can be applied not only to tramway and railway infrastructure, but also to industrial facilities and transhipment terminals.

The presented crane-track slab is a prefabricated reinforced-concrete element integrated with an S100 rail, designed for the construction of rail tracks for handling and crane equipment, particularly at intermodal, port and logistics terminals.

Prefabrication enables precise execution of the element and accurate positioning of the rail already at the production stage, followed by delivery of ready-to-install modules to the construction site. The solution demonstrates the potential to apply CONTRACK know-how wherever durable rail surfaces capable of withstanding high operational loads are required.

 

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