The Netherlands has taken a major step in sustainable infrastructure by installing over 30 kilometres of fully circular steel rails between Hoofddorp and Leiden. These rails, made entirely from recycled Dutch railway steel, set a new benchmark for circular design. They also show how large-scale projects can actively reduce environmental impact.

Lower-Carbon Steel Production

Traditional steel rails come from coal-fired blast furnaces, which emit high levels of CO₂. In contrast, the new rails use electric arc furnaces (EAFs) and scrap steel from decommissioned tracks. This process cuts CO₂ emissions by up to 65% compared to conventional production. As a result, the project delivers significant climate benefits while maintaining the high durability and safety standards of the rail network.

Closing the Loop in Rail Materials

ProRail, together with contractors and market partners, developed this project from concept to installation. French steelmaker Saarstahl produced the rails, and Voestalpine Track Solutions Netherlands supplied them. This subsidiary of Voestalpine runs a recycling plant in Hilversum. Here, teams process old rail components into high-quality raw materials. In turn, sending end-of-life rails directly back to the steel producer keeps valuable metal in the production loop, avoids waste, and encourages new logistics and work methods.

From Pilot to Industry Standard

The Noord-Holland project marks the first of several pilots planned for 2025. Later this year, ProRail will publish clear guidelines for using circular rails in procurement and maintenance contracts. In addition, the organisation aims to increase the proportion of sustainably produced steel in the Dutch rail sector. Progress will also depend on industry factors such as the availability of suitable scrap steel.

“With these circular rails, we take a major step towards a climate-neutral railway infrastructure,” said Janneke Vogels, ProRail’s Director of Sustainability. “We want to work with the sector to build a future-proof and sustainable rail network.”

For architects, landscape designers, and product developers working in infrastructure and public space, this project illustrates how recycled materials and low-carbon production methods can drive the transition to a circular economy. Therefore, the same approach could inspire sustainable solutions well beyond the railway sector.

Source: ProRail
Photo: Shane van Hattum / Prorail / duckdev