Modern Vibro-acoustic Insulation Systems by EPUISORAIL for Tram and Rail Infrastructure

As the EPUFLOOR Group, we began our operations in 2005, offering modern sports and recreational surfacing systems to the Polish market. From the very beginning, we have cooperated with leading manufacturers of elastomers used in sports surfaces. This collaboration directed our attention toward vibroacoustic isolation solutions based on permanently elastic materials applied in general and transport construction.

In 2010, we expanded our portfolio to include vibroacoustic isolation systems for general construction. We provide comprehensive support covering technical consultancy, selection and supply of optimal solutions, and recommendations of certified contractors.

Expansion into Rail Infrastructure Systems

The dynamic growth of public transport and increasing requirements to reduce the impact of rail vehicle traffic on surrounding areas led us to extend our activities to vibroacoustic isolation systems dedicated to rail infrastructure.

Initially, our offer included under ballast mats made of elastomers, where the permanently elastic layer consisted of foamed polyurethane or recycled rubber granulate bonded with polyurethane resin. The first mats supplied by us were installed in 2017 during the modernization of railway line E30 on the Kraków Mydlniki – Kraków Towarowy section.

The specific nature of rail infrastructure solutions resulted in the establishment of a specialized EPUISORAIL division, dedicated exclusively to the design and development of vibroacoustic isolation systems for railway tracks.

EPUISORAIL: Design and Manufacturing of Vibroacoustic Isolation Systems

The EPUISORAIL division is responsible for the design, production and distribution of advanced vibroacoustic isolation systems intended for rail applications.

Our foundation is the delivery of thoroughly tested, efficient solutions developed for the Polish market in cooperation with renowned elastomer manufacturers. We consistently expand our range of vibroacoustic isolators designed and manufactured on the basis of:

• environmentally friendly technologies,

• low emission materials,

• solutions supporting the circular economy, including material recycling.

Current EPUISORAIL Product Portfolio

1. EPUTRACK Under Ballast Mats
   EPUTRACK mats are manufactured from recycled rubber granulate and or rubber fibers. A wide range of standard densities from 420 to 730 kg per cubic meter and thicknesses up to 50 mm enables precise adjustment of parameters to specific project and investor requirements.

2. PURASYS Under Ballast Mats
   These mats are produced from foamed polyurethane by the renowned company KRAIBURG PURASYS. The solution ensures stable elastic properties and high vibration damping efficiency.

3. EPUMAT PU Under Slab Mats
   EPUMAT PU consists of under slab mats made from recycled polyurethane composite, intended for track structures requiring effective vibroacoustic insulation.

4. EPUPROFILE EVO Rail Profiles
   Developed in 2022, EPUPROFILE EVO rail profiles are manufactured from recycled rubber granulate and fibers. They are designed to provide both vibroacoustic and electrical insulation of the rail from other elements of the track structure.

5. EPUFLEX ST Rail Fastening System
   Introduced in 2024, the EPUFLEX ST system includes primers and polyurethane resins for permanently elastic continuous or discrete rail fastening in concrete substructures. The system also ensures the required electrical insulation of the rail from other track components.

6. EPUSLAB Prefabricated Slab System
   In 2025, we introduced EPUSLAB prefabricated integrated road and rail slabs. The system combines the main load bearing layer of the track structure with the road wearing course, simplifying the construction process. The solution is also available in large format and turnout slab versions.

7. EPU USP Under Sleeper Pads
   EPU USP under sleeper pads are used to reduce the dynamic impact of rail vehicles on surrounding areas, increasing user comfort and limiting vibration transfer to infrastructure.

Planned Development: EPUPROFILE EVO GREEN

In 2026, we plan to introduce the EPUPROFILE EVO GREEN system dedicated to green track applications. The modified rail profiles, combined with specially designed fastening covers, are intended to ensure insulation of the rail and fastening elements from organic track structure layers.

The system is currently in the final design phase. Alternative models developed using 3D printing technology are being tested. Completion of the testing phase is planned for the first quarter of 2026.

Experience and Market Trust

High product quality, stability of technical parameters, optimized commercial offers and timely deliveries have enabled us to gain the trust of numerous clients. This has resulted in total sales of:

• approximately 350,000 m² of under ballast mats, mainly EPUTRACK,

• approximately 35,000 linear meters of EPUPROFILE EVO rail profiles,

• approximately 10,000 EPU USP under sleeper pads,

• approximately 15,000 kg of EPUFLEX ST resin,

• more than 3,000 m² of EPUSLAB prefabricated slabs, including large format and turnout slabs.

Comprehensive Vibro-acoustic Insulation Systems for Tram and Rail Infrastructure

EPUFLOOR and the EPUISORAIL division consistently develop modern vibroacoustic isolation systems for rail infrastructure, responding to increasing investor requirements and the need for sustainable transport development. Our solutions combine durability, effective vibration damping, operational safety and environmental responsibility.