New lightweight cable troughs for faster construction: Piloting near Aachen
In the Aachen area, DB InfraGO is using newly approved lightweight cable troughs for the first time as part of the sector initiative Digitale Schiene Deutschland. Over around three kilometres of open track, they were laid significantly faster than conventional concrete ducts – an advantage for the construction process and efficiency on the construction site.
Around three kilometres of new cable troughs on the open route
We are modernising the rail infrastructure throughout Germany with numerous construction projects in order to make the railway more attractive and reliable for all customers. Our aim is to continuously make construction processes more efficient – both in large-scale projects and through targeted, innovative improvements in detail. A current example of this is the first use of new lightweight cable troughs in the Aachen area. During an initial track possession at the beginning of March, the company MTB GmbH laid the new cable troughs on around three kilometres of open track along the Aachen West section.
Cable troughs are an important part of the rail infrastructure. They guide and protect cables that are required for control and safety technology, telecommunications and energy supply.
Compared to classic cable ducts made of concrete, the new systems can be installed much more quickly. The new cable troughs have tripled the laying capacity per shift: Up to 200 metres instead of 60-80 metres as with concrete ducts.
Build faster and organise construction sites more efficiently
One reason for the speed advantage is the lower weight of the new cable troughs. This makes them much easier to transport, cut to size and use. In addition, a "road-rail excavator" is no longer required for laying the cables, so they can be used for other tasks in parallel. Construction processes can therefore be better coordinated and construction sites can work more efficiently overall.
Modern material instead of classic concrete channels
The Furukawa ("Green Trough") brand cable ducts approved at the end of 2025 are made of recycled HDPE plastic. They were further developed as part of the DB "Accelerated cable earthworks"-project and approved for use on DB lines for the first time. Unlike the classic concrete ducts that have been used for many years, they are lighter in weight and have custom-fit, lockable covers that provide additional protection for the laid cables. They are also more robust than previous plastic cable ducts – they are impact-resistant, flame-retardant and designed for a technical service life of over 50 years. They therefore fulfil the requirements for a modern and robust infrastructure along the route in the long term.
"We were the first project in the West to successfully test the new system as a pilot project. It is an important step, especially in the key area of cable earthworks, to bring new and more efficient solutions into use. What is particularly important here is that the advantages we promised ourselves in theory are also evident in use on the construction site. With innovations like these, we are helping to further develop the infrastructure and minimise the impact of future construction sites for our customers."
Stefan Müskes, Head of Technology Portfolio West, DB InfraGO AG
"We are always endeavouring to bring innovative solutions to the construction site. The new cable ducts are a good example of this: lighter, quicker to install and more efficient overall in the construction process than conventional systems. The lightweight cable ducts can be transported much more efficiently than concrete ducts, which are neither stackable nor flexible to move. This allows us to work faster on the construction site and organise processes better."
Armin Taherian, Management/construction management, MTB GmbH
The experience gained in Aachen provides important insights for future projects of the Digitale Schiene Deutschland and shows how new construction methods can help to modernise infrastructure more efficiently. In the medium term, a specialised laying train for track renewal will also be available for this system, which is currently still in a test phase: More information and a video on LinkedIn.
