Structural Renewal of Track Supports on Madrid Metro Line 6 Using High-Performance PROPAM® GROUT Mortars

Structural Renewal of Track Supports on Madrid Metro Line 6 Using High-Performance PROPAM® GROUT Mortars

LOCATION: Madrid Metro – Line 6
YEAR OF WORKS: 2025
OWNER: Madrid Metro
CONTRACTOR – LOT 1: Contratas y Ventas / Vías y Construcciones
CONTRACTOR – LOT 2: Tecsa Empresa Const. / COMSA

Track Support Renewal and Anchoring System Using PROPAM® GROUT 140 HP and PROPAM® GROUT 140R

Introduction

The renewal of operational railway infrastructure requires technical solutions that ensure structural strength, long-term reliability and continuity of service without compromising train operations or safety.

On Line 6 of the Madrid Metro, a major project is under way to deliver the comprehensive renewal of the line, including its track supports, ensuring optimum operating conditions, passenger comfort and the long-term durability of the infrastructure.

For this purpose, highly flowable structural grouts from the PROPAM® GROUT range are being used. These products are designed to provide high strength, zero shrinkage and excellent performance under the dynamic loading typical of railway environments.

Project Description

The works involve replacing the existing supports with a new bonded plate support system. The work is carried out either:

• during maintenance windows, using rapid-setting grout (PROPAM® GROUT 140R); or
• during line closures, using high-strength, normal-setting grout (PROPAM® GROUT 140 HP).

The works include:

• Controlled removal of the existing supports.
• Installation of new, state-of-the-art track supports.
• Anchoring and fixing using anchor bolts and purpose-designed chemical anchors.
• Installation of purpose-built formwork.
• Grouting beneath the plates to ensure correct load transfer between the rail and the structure.

The primary aim is to improve track safety, stability and ride comfort, while enhancing dynamic performance and reducing future maintenance requirements.

Total Volume of Product Used

PROPAM® GROUT 140 HP
A total of 5 million kg of this flowable, non-shrink grout was used. Developed specifically for demanding structural grouting applications, it provides mechanical strength, dimensional stability and a controlled return to service.

PROPAM® GROUT 140R
At the same time, work was carried out during maintenance windows, where faster setting times were required.
A total of 2 million kg of PROPAM® GROUT 140R was used. The product is formulated to provide high flowability, excellent adhesion and rapid strength development.

Objectives of the Works

• To renew and modernise the structural track supports.
• To bring the infrastructure into line with current safety and comfort standards.
• To ensure correct load transfer to the structure.
• To optimise track durability through the use of certified, high-performance grouts.
• To integrate the works with Metro operations while minimising disruption to passengers.

Project Challenges

• Night-time working during maintenance windows and line closures, with very limited access periods due to train operations.
• Continuous supervision and monitoring to ensure correct application.