Tracks Made Tougher: How Old Tyres Are Reinventing Railroads

By: | July 25th, 2025

The recycled rubber grids on a stretch of test track laid at Chullora NSW. Photo: Rakesh Malisetty. (Image by Rakesh Malisetty.)

The University of Technology Sydney (UTS) is pioneering a world-first solution to enhance railway resilience as well as tackle the growing problem of tyre waste. Led by Distinguished Professor Buddhima Indraratna, UTS researchers have developed an innovative system utilizing recycled tyres to protect railway tracks from degradation.

The Dual Challenge: Track Damage & Tyre Piles

Traditional railway tracks suffer from ballast degradation due to heavy train loads, leading to costly maintenance, frequent track closures, and reduced stability. This problem is compounded by Australia’s waste challenge, with over 50 million end-of-life tyres discarded annually, posing a significant environmental burden.

UTS’s Innovative Solution: Rubber Shock Absorbers

The UTS innovation integrates rubber shock absorbers and grids made from recycled tyres directly beneath the tracks. This patented technology significantly:

  • Protects the ballast, preventing pulverization and extending track lifespan.

  • Distributes train loads more effectively, preventing soil settlement.

  • Reduces vibration and noise, offering a smoother ride and potential community benefits.

Proven Success and Future Horizons

A two-year trial on a Sydney Trains freight line, a collaboration with Sydney Trains, Transport for NSW, EcoFlex, and Bridgestone, demonstrated remarkable success. Sections with the recycled rubber underlay showed significantly less degradation and greater stability compared to conventional tracks. Consequently, this translates to substantial savings in maintenance costs and improved network reliability.

This project offers a powerful circular economy solution, transforming waste into valuable infrastructure. With a new $740,000 Australian Research Council Linkage Project grant, the UTS team will further test the technology in challenging areas like bridge approaches and junctions, aiming to set new standards for rail durability and sustainability.

Nidhi Goyal

Nidhi is a gold medalist Post Graduate in Atmospheric and Oceanic Sciences.

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