The Dutch rail network operator ProRail has achieved a global milestone in sustainable infrastructure by introducing the world’s first 100% recycled copper contact wire. The innovation marks a significant step towards circular rail construction and material reuse in large-scale infrastructure projects. The installation takes place on the Zeeuwse railway line between Roosendaal and Vlissingen, in collaboration with Strukton Rail, Railtech BV, and La Farga—the Spanish company behind the copper recycling technology.

A Major Step in Circular Copper Use

A total of 36 kilometres of double overhead line is being replaced this year with completely recycled copper wire, known as Genius. Compared to conventionally mined copper, the recycled version results in a 92% reduction in CO₂ emissions, 99% less water use, 89% less fossil fuel consumption, and a 99% reduction in sulphur dioxide emissions. The environmental benefit of replacing 75 kilometres of fully recycled overhead line equates to the annual CO₂ absorption of 20,000 trees.

The Genius wire meets the European standard EN50149 and ProRail’s strict technical requirements (SPC00069). It offers identical mechanical and electrical properties to traditional contact wires, making it a reliable, sustainable alternative without compromising performance.

Collaboration Driving Innovation

The project demonstrates how international collaboration can accelerate the transition to circular infrastructure materials. The Genius wire was first approved for application at the InnoTrans trade fair in Berlin (2024), following years of research and testing. La Farga developed the technology enabling complete copper recyclability, Railtech BV supplied the materials, and Strukton Rail executed the installation for ProRail.

According to Janneke Vogels, Director of Sustainability at ProRail, “By using recycled copper from a circular process, we are taking concrete steps toward a climate-neutral and circular rail infrastructure.”

Towards a Circular Rail Future

ProRail plans to integrate 100% recycled copper wire in future tenders and maintenance contracts, further increasing the proportion of circular materials in the rail sector. The initiative supports ProRail’s goal to achieve at least 55% CO₂ reduction by 2030 (compared to 2015) and contributes to the EU’s climate neutrality objectives.

Tjark de Vries, Managing Director of Strukton Rail Netherlands, calls the project “a world first that sets an example for the entire rail sector,” while Dick van Harten, CEO of Railtech, emphasises that circularity is “in our DNA” and that the Genius wire represents “an inspiring step towards a future-proof, fully circular rail system.”

Source: ProRail
Photo: Nic Wood