Slab Track: This railyway runs fast here

The Delhi–Meerut RRTS corridor exemplifies next-generation infrastructure in India, combining proven performance, local integration, and international collaboration to enhance regional mobility across the National Capital Region, or NCR. The National Capital Region Transport Corporation (NCRTC), a joint venture between the Government of India and the state governments of Delhi, Haryana, Rajasthan, and Uttar Pradesh has been entrusted with the task of implementing the Regional Rapid Transit System (RRTS) across the National Capital Region (NCR) of India. PORR entered this new market as a system provider and technology partner rather than a traditional contractor, delivering comprehensive technical advisory services, including system integration, technology adaptation for Indian conditions, and support across track design, component specification, quality assurance, and implementation. NCRTC selected PORR’s proven Slab Track Austria system for its superior quality, cost-effectiveness, and fast installation. 

Post-manufacture, the precast slab panels underwent rigorous inspection by NCRTC’s dedicated quality assurance team. They were then either stored at the precast factory or transported to designated logistics and storage sites near the installation zones along the corridor. This decentralized storage strategy ensured timely availability and minimized transport delays during installation.

The installation of PORR STA slab track panels offered significant advantages over traditional track systems commonly used in the Indian railway sector:

• High prefabrication degree—approximately 85% of concrete volume cast off-site resulting in minimal on-site work force requirements. On-site activities are limited to placement and minor SCC (self-compacting concrete) infill—drastically reducing track possession time and disruptions.
• Use of simple gantry cranes for panel installation, enabling quick, safe, and accurate placement.
• On bridge or tunnel sections, only a thin layer of self-compacting concrete (SCC) was needed beneath the slab, eliminating the need for vibration and reducing alignment disturbance risks.
• Local work force teams were swiftly trained in the new installation techniques, achieving installation rates of up to 100 meters per day—a substantial improvement over traditional methods.

Given the scale, length, and structural diversity of the Delhi–Meerut RRTS corridor, the installation of the PORR STA slab track system faced several technical and logistical challenges. These were successfully addressed through effective collaboration, engineering adaptability, and continuous innovation. 

Training

The PORR Slab Track system demands exceptionally precise construction and the use of installation techniques which were unfamiliar to Indian contractors and work forces at the project start. To bridge the knowledge gap, PORR specialists provided extensive hands-on training to local contractors and workers. This enabled rapid skill development and smooth adaptation of the technology. The system’s intuitive design, combined with structured training programs, allowed local teams to quickly master installation procedures and achieve high productivity.

Interface management

Successful slab track installation depends on the timely and precise completion of viaducts, tunnels, and stations. Delays or deviations in civil works can directly impact the sequencing of slab installation and could lead to increased cost and schedule risk. To manage these dependencies, early planning and a high level of interface coordination with civil and systems contractors was necessary. With support from PORR, the NCRTC team demonstrated strong engineering capacity, and interfaces were managed proactively to avoid major disruptions.

Adaptability in constrained working conditions

Working in densely populated urban areas presented space limitations, access challenges, and heightened safety and environmental considerations. The adaptable PORR STA system proved particularly effective in urban settings due to its high degree of prefabrication—over 85% of the track volume was manufactured off-site. This reduced the need for large quantities of rebar and fresh concrete on-site, significantly minimizing disruption, traffic interference, and environmental impact.

Strict quality and alignment requirements

The PORR STA system provides highly accurate alignment to support high-speed operations. Millimetre-level precision in real-world construction conditions was achieved using advanced survey techniques and strict quality control procedures.

Digital quality assurance

Each slab panel was assigned a unique identification number and tracked through a cloud-based system. This ensured full traceability of concrete properties, embedded components, and fastening systems. The digital QA/QC approach supported rigorous auditing and compliance with international standards throughout the installation process.

The implementation of Phase 1 of the Delhi–Ghaziabad–Meerut RRTS corridor marks a significant milestone in India’s transportation modernization efforts. As the first operational semi-high-speed regional rail system in the country, the project has not only demonstrated technical feasibility but has also set new benchmarks in project delivery, innovation, and stakeholder collaboration.

Despite the project’s complexity and the diverse range of challenges, the PORR Slab Track Austria technology demonstrated a high level of adaptability, reliability, and efficiency. Its modular design, factory-controlled quality, and minimal on-site requirements enabled rapid installation without compromising precision or safety. The successful execution of slab track installation within the planned time and budget underscores the system's suitability for India’s future high-speed and urban rail infrastructure. The system is designed with a long design life (up to 100 years) and low maintenance, reducing lifecycle costs and downtime, a crucial advantage as India builds a scalable, modern high-speed network.