CONTRACK at Zawiszy Square in Warsaw

CONTRACK is taking the next step in its technological development. After six projects in five Polish cities, we are ready to build one of the most important junctions in central Warsaw, crucial for car and tram traffic: Zawiszy Square. The prefabricated elements are being installed by KZN Rail .

Prefabrication of key elements of the tram switch system at this key location for traffic in the capital will allow for precise and rapid assembly at their final destination – almost like ready-made building blocks. This will help the capital avoid weeks of road closures. The large-scale prefabricated elements have already been trial-laid at the manufacturer's assembly yard in Krakow and then shipped by rail to Warsaw. There, on a Warsaw Tram siding, they will await the commencement of the first phase of renovation.

4.08-10.08 Stage III

All 121 prefabricated CONTRACK panels have been installed. Normal traffic has been restored throughout Zawiszy Square. KZN Rail is already carrying out finishing work.

The entire Zawiszy Square interchange, despite an initial schedule change forced by heavy rains, was completed in just five weeks. Together with KZN Rail, we set a new standard: lightning-fast renovation .

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18/19.07-3.08.2025 Stage II

The phase is divided into two phases: Phase II A and Phase II B, due to the extensive nature of the work. It includes replacing the tracks at three stop platforms located directly next to the roundabout. After installing the CONTRACK slabs and partially reopening traffic, work began on the remaining stop infrastructure.

See what it looked like at this stage of laying large-scale prefabricated CONTRACK panels! VIDEO REPORT

12-17/07/2025 Stage I slabs laid

Following a schedule change forced by heavy rains, precast CONTRACK panels from the first phase of work were laid at Zawiszy Square on Saturday and Sunday. The panels were precisely leveled in their final location. Grouting was performed, steel turnout components were installed, and welding work was completed. On July 16, the material for the continuous elastic rail fastening was introduced. The precast panels are ready for a trial run, which will take place overnight from Friday to Saturday. The official completion of the first phase of work will take place on July 18, 2025.

The entire junction will be arranged like blocks

To date, CONTRACK technology has been used in cities such as Poznań, Bytom, Mysłowice, Ruda Śląska, and Kraków (tram crossing). However, this is the first such extensive use of the technology – as many as 121 large-scale CONTRACK precast reinforced concrete slabs will be installed at Zawiszy Square, with a total area of ​​approximately 1,600 m² . This is roughly the size of two Orlik sports fields. Approximately 540 m³ of concrete was used to construct them, and the largest slab measures 23 m² . Of the total, 12 slabs were made with hybrid reinforcement, while 109 were made with classic steel reinforcement. This will result in the installation of three double-track turnouts and one single turnout in Warsaw.

Double quality control – trial layout of the system at the assembly site

CONTRACK panels are each designed for a specific turnout, crossing, or—as in the case of Zawiszy Square—an entire junction. There are no ready-made, mass-produced solutions. To meet the highest standards, ensure the best possible initial quality, and ensure the longest possible lifespan of the panels, CONTRACK employs double quality control.

The first phase of quality control is performed immediately after production is completed – the geometry of each individual slab is carefully checked. The second phase of quality control was observed at the CONTRACK yard – all slabs from a given construction stage (in this case, Stage I, consisting of 15 slabs) are trial-laid and fitted together with the steel turnout components. This ensures millimeter-precision accuracy and smooth completion of work at the final construction site.  A demonstration of the first stage's panel fitting took place on June 11, 2025. Representatives of Tramwaje Warszawskie, among others, participated in the event, checking the level of technological readiness for installation. See the event report .

Logistics - we free the roads

The prefabricated tram elements are traveling from Krakow to Warsaw by rail . In the capital, they will be transferred to road transport and delivered to the construction site. This is the first time this solution has been implemented, aiming to reduce truck traffic on the roads and reduce the risk of traffic jams.

For comparison, if the same project were to be carried out using traditional technology, it would be necessary to engage as many as 70 concrete mixer trucks, which would enter the center of Warsaw, disrupting the flow of traffic.

A range of specialized logistics solutions will be utilized on-site to ensure the precise placement of the slabs at their final location in such a short time. The logistics refined during previous CONTRACK installation projects allow for efficient work in the most demanding areas: where rapid restoration of traffic (especially vehicular traffic) is required, where workspace is limited (both vertically and horizontally), and where installation requires high precision.

The following will be used, among others:

- ORMIG 55T hall crane adapted to work in halls and tight spaces, lifting capacity up to 60 tons;

- HDS MAN/Effer 2750 3S - with a lifting capacity of up to 32 tons;

- a dedicated PWP gantry system that allows work under the overhead line in a small working area.

Stages of work at Zawiszy Square and traffic organization

The investment has been divided into three stages. Each stage will include the introduction of a detour for vehicle traffic.

Phase I: Renovation of the western section of the Zawiszy Square tracks. Tram traffic will be restricted to Towarowa Street and Jerozolimskie Avenue. Trams will not run between Zawiszy Square and Narutowicza Square. Car traffic will be managed through a temporary U-turn on Grójecka Street. Fifteen precast reinforced concrete turnout slabs and 18 precast reinforced concrete straight slabs will be installed. This phase lasts one week.

Stage II: Renovation of the eastern side of the tracks. Tram traffic will be diverted via Towarowa and Grójecka Streets. Trams will not run between Zawiszy Square and Starynkiewicza Square. This stage is longer because it also includes replacing the tracks at three tram stop platforms located directly next to the roundabout. Vehicular traffic will be diverted via a detour. The first part of stage IIa will last approximately one week, after which traffic in the square will be partially reopened. The stage lasts two weeks.

Phase III: concerns the northern side of Zawiszy Square. Tram traffic will be maintained through Jerozolimskie Avenue and Grójecka Street. Trams will not run between Zawiszy Square and Kercelak. Vehicular traffic will be diverted through a temporary U-turn in the Towarowa Street lane. Phase two will last one week.

Paving and finishing works are expected to be completed by the end of September.

Why CONTRACK technology?

The current technology for constructing tram switches required multiple layers of concrete poured directly on site, with a setting time of 28 days (concrete curing). During this time, both tram and road traffic would have to be suspended at the construction/renovation site. The often shortened waiting time for this process on construction sites results in significant surface degradation over the years.

CONTRACK relocates this time-consuming panel production process to the manufacturer's facilities. Ready-made panels are delivered to the construction site and assembled almost like building blocks. This reduces the installation time from a month to even a weekend (depending on the complexity of the turnout or crossing system).

It's precisely in places like Zawiszy Square that CONTRACK is best suited. This is one of the most critical intersections in the capital – with intense tram and car traffic, time pressures associated with development, and very limited space.

Zawiszy Square – what next?

The introduction of CONTRACK technology at Zawiszy Square is a continuation of the successes from previous projects – including those in Mysłowice, Kraków, Bytom and Poznań, where work times were shortened from entire weeks to the so-called weekend mode.

This will also confirm that modern prefabricated panels are the future of tram infrastructure in large cities – fast, precise, durable, and minimally disruptive to residents. The July renovation at Zawiszy Square is the best proof of this.

Contrack is a technology developed with the participation of European Union funds and the support of the National Centre for Research and Development.