Adif Alta Velocidad has taken a new step in the modernization of the Madrid–Barcelona high-speed line by awarding the first contract for the supply of aerodynamic railway sleepers, a technology developed in Spain that could enable trains to reach speeds of up to 350 km/h.
The contract is worth EUR 112.76 million and covers the manufacture and delivery of over 680,000 sleepers for the infrastructure renewal on the Mejorada del Campo–Calatayud section.
Although Spain’s railway infrastructure manager has not announced the name of the company that won the contract, it is known that Travipos, the Spanish subsidiary of German manufacturer RailOne, has obtained authorization to manufacture the new model of sleepers. The design was included in Adif’s Register of Validated Products after the completion of testing and certification phases.
The new generation of sleepers, called the “aerotraviesa,” was designed to address the challenges posed by trains traveling at very high speeds. When trains exceed 300 km/h, the aerodynamic flows created beneath the vehicle can carry away ballast particles, a phenomenon known in the industry as “ballast blow.” This can cause damage to trains and infrastructure, as well as additional maintenance costs.
The contract awarded by Adif calls for the production of 680,400 sleepers, along with the associated elastic elements, as well as their transport and storage. The work is divided into four lots: Mejorada del Campo–Brihuega (232,400 units), Brihuega–Alcolea (143,150 units), Alcolea–Ariza (166,250 units), and Ariza–Calatayud (138,600 units).
Aerodynamic Sleeper Technology
The Madrid–Barcelona line modernization program is not limited to sleeper replacement. Adif is simultaneously carrying out work to renew the rail fastening systems, as well as interventions on the Benamira and Río Blanco viaducts, located in the province of Soria. These investments aim to increase the reliability of the infrastructure and prepare the line for operation at higher speeds.
Aerodynamic sleepers represent one of the most important innovations developed in recent years for the Spanish rail network. The new sleeper profile reduces the flat surface exposed to the air currents generated by high-speed trains and increases the distance between the top of the sleeper and the ballast layer. According to data published by Adif and RailOne, this configuration reduces aerodynamic loads in the ballast area by 21%.
The result is a significant reduction in the risk of loose ballast being lifted from the track, allowing trains to operate at higher speeds without compromising traffic safety. According to studies conducted as part of the project, the use of aerodynamic sleepers can allow for an increase of up to 12% in operating speed without the risks associated with the “ballast lift” phenomenon.
The development of the new sleeper is the result of collaboration between Adif and Travipos, within an innovation project carried out as a public-private partnership. To enable industrial production, Travipos adapted the design developed by Adif to its manufacturing lines in Tarragona, without altering the product’s technical performance.
A pilot section equipped with aerodynamic sleepers has already been installed on the Madrid–Barcelona high-speed line, and the results obtained have confirmed the advantages of the new solution. Based on these tests, the sleepers have been officially validated and included in Adif’s catalog of approved products.
With this investment, Spain continues its preparations for commercial operation at 350 km/h on one of Europe’s most important high-speed lines, while strengthening the Spanish railway industry’s position in the field of high-speed infrastructure technologies.
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