Summer driving risks and how infrastructure should respond

Summer changes the usual driving conditions. Long-distance journeys, traffic in tourist areas and overnight travel intended to avoid the hottest hours all increase. At the same time, high temperatures can increase fatigue, reduce concentration and place greater mechanical demands on vehicles.

This combination of factors reduces the time available to react to pedestrians, congestion, bends, obstacles or unexpected changes in road conditions. Summer road safety therefore depends not only on the driver and vehicle maintenance. Infrastructure must also help detect risks, provide timely warnings and reduce the consequences of a potential accident.

Heat, fatigue and reduced reaction capability

High temperatures can cause tiredness, drowsiness and irritability, particularly during long journeys. When a driver spends several hours at the wheel, their ability to remain attentive and react to an unexpected event may be reduced.

Heat also affects the vehicle. Tyres operate at higher temperatures, and any existing problem involving pressure, wear, overloading or deterioration can increase the risk of a puncture or structural failure.

An apparently manageable situation, such as congestion beyond a bend or a pedestrian beginning to cross, can therefore become a serious danger when reduced attention, high speed and insufficient braking distance occur together.

Driving at night during the summer

During the summer months, night-time journeys associated with leisure activities, holidays and travel back from tourist areas become more frequent. However, driving at night reduces the distance at which certain hazards can be identified.

Pedestrians, cyclists, stationary vehicles and obstacles outside the main beam of the headlights may be detected too late. This is particularly relevant on roads passing through towns and villages, approaches to populated areas, leisure districts and pedestrian crossings with limited lighting.

Conventional signs may not be sufficient at these locations. A fixed sign always conveys the same message, regardless of whether an immediate hazard is present. Adaptive road lighting and intelligent signs, by contrast, can improve visibility and activate a warning when a risk is actually present.

ITS for a dynamic response

Intelligent Transport Systems, commonly known as ITS, combine sensors, communications, lighting and signalling devices to detect what is happening on the road and respond in real time.

Their main advantage is that they turn infrastructure into an active element. Instead of simply displaying a permanent sign, the system can recognise a specific situation and generate an appropriate warning.

Possible applications include:

  • Detecting pedestrians at critical crossings.
  • Enhancing bend warning signs at night.
  • Warning drivers about excessive speed.
  • Providing warnings about congestion or stationary vehicles.
  • Activating lighting in conditions of poor visibility.
  • Detecting impacts against restraint systems.
  • Collecting traffic and mobility information.

Devices such as PlugSmart® Pro can turn a conventional restraint system into an intelligent element capable of detecting risks and generating warnings from the infrastructure itself.

These solutions are particularly useful during the summer, when traffic volumes and travel patterns vary according to the time of day, the day of the week or tourism activity.

Dynamic LED road studs at pedestrian crossings

Collisions involving pedestrians on roads through populated areas and in urban environments can be reduced through dynamic LED road stud systems. When a sensor detects that someone is approaching a pedestrian crossing, it can activate a light signal directed towards approaching drivers.

The purpose is to improve the visibility of the crossing point and attract attention at the precise moment when a risk is present.

This system can:

  • Improve the night-time visibility of the crossing.
  • Warn drivers that pedestrians are actually present.
  • Prevent drivers from becoming accustomed to a permanently active signal.
  • Adapt its operation to specific schedules or conditions.
  • Record data about the use of the crossing.

Metalesa’s Metaurban® SMART parapet can integrate sensors and LED lights to generate warnings on the carriageway. Its applications include pedestrian detection, excessive speed warnings, lighting for pedestrian and cycle routes, and alerts in the event of fog, congestion or impacts.

The restraint system therefore ceases to be an exclusively passive element and becomes part of connected infrastructure.

Risk of tyre failures involving heavy vehicles

High temperatures can aggravate tyre maintenance problems. In a heavy vehicle, a sudden failure can cause a loss of control that is difficult to correct because of the vehicle’s considerable mass and the energy generated while it is moving.

The risk increases when an incident occurs on a motorway, bridge or viaduct. At these locations, a vehicle leaving the carriageway can have particularly serious consequences.

Infrastructure should therefore incorporate steel bridge parapets with a containment level appropriate for the expected traffic. These systems are designed to contain and redirect vehicles, reducing the possibility of them passing beyond the edge of the structure.

Metalesa’s META16 steel bridge parapet has an H3 containment level and is intended to protect areas carrying vehicles with a high mass. One example of its application is the installation of three kilometres of META16 on the A-23 viaducts.

The effectiveness of these systems also depends on correct installation, the strength of the anchors and the appropriate treatment of transitions and terminals.

Active and passive safety

The response to summer driving risks must combine two levels of protection.

ITS, sensors and LED devices act before an accident occurs. Their role is to detect a dangerous situation, improve the information available and give the driver more time to react.

Parapets and restraint systems act when an accident can no longer be prevented. Their purpose is to contain the vehicle and reduce the consequences of leaving the carriageway or losing control.

Both strategies must work together:

  • Active safety anticipates the risk.
  • Passive safety limits the severity of the impact.
  • Connectivity enables data to be collected.
  • Maintenance preserves the performance of the system.

Infrastructure prepared for summer

Summer mobility combines heavier traffic, high temperatures, fatigue and increased night-time travel. In this scenario, infrastructure must be capable of adapting to actual road conditions.

ITS and dynamic LED road studs can reinforce warnings during periods of increased risk. High-containment parapets, meanwhile, provide a final layer of protection in accidents involving heavy vehicles on motorways, bridges and viaducts.

Metalesa develops solutions that integrate active and passive safety by combining restraint systems, sensors, lighting and intelligent signalling.

The objective is to move towards roads that can detect danger, warn users and reduce the consequences when an accident cannot be prevented.

by javier

Challenges and solutions in the design of vehicle restraint systems for cyclists and motorcyclists

Motorcyclists are among the most vulnerable road users. Unlike the occupants of a car, they do not have a protective structure capable of absorbing impact energy. As a result, a fall or run-off-road collision can have particularly serious consequences.

The studies on motorcycle collisions on interurban roads published by Forenvision analyse accidents recorded between 2017 and 2024. They pay particular attention to run-off-road collisions, one of the most severe types of accident involving motorcycle users.

The figures illustrate the scale of the problem. In 2024, 478 motorcycle or moped users were killed in Spain, accounting for 26.8% of all road traffic fatalities. Spain also has more than 4.3 million registered motorcycles.

This situation makes it necessary to design roads that not only seek to prevent accidents, but also reduce their consequences when they occur.

1. Run-off-road collisions: a particularly dangerous scenario

A vehicle may leave the road for many different reasons, including inappropriate speed, loss of grip, distraction, evasive manoeuvres, the condition of the road surface or complex road geometry.

For motorcyclists, the dynamics of a collision are usually different from those involving four-wheeled vehicles. After losing control, a rider may fall onto the carriageway and slide until they strike a safety barrier or another object located on the roadside.

Conventional steel safety barriers are designed to contain and redirect vehicles. However, their posts can become highly dangerous impact points for someone sliding along the ground. This risk is commonly known as the guillotine effect because of the high concentration of forces that may be exerted on the body.

Vehicle restraint engineering must therefore consider not only the behaviour of the vehicle, but also the possible interaction between the motorcyclist and the infrastructure. In this context, road restraint systems must be selected according to the type of road, its speed, the road users present and the foreseeable consequences of a vehicle leaving the carriageway.

2. What are Motorcycle Protection Systems?

Motorcycle Protection Systems, commonly known as MPS, are devices normally installed along the lower section of steel safety barriers.

Their purpose is to close the gap between the barrier and the ground, cover the posts and create a continuous longitudinal surface. This helps prevent direct impacts against rigid components and reduces the severity of injuries.

A properly designed MPS can:

  • Prevent direct contact between the motorcyclist and the barrier posts.
  • Reduce the presence of exposed edges and sharp surfaces.
  • Distribute the impact across a larger surface.
  • Guide the rider’s body along the system.
  • Prevent the rider from passing underneath the barrier.

Metalesa has developed the Metaurban® steel parapet with a Motorcycle Protection System, a solution that combines vehicle containment with specific protection for road users who may slide along the carriageway after falling.

The application of these solutions is also discussed in the article Parapets also protect motorcyclists, which examines the need to incorporate systems adapted to this vulnerable group.

3. Where should MPS be installed?

The installation of Motorcycle Protection Systems should be based on a specific risk assessment. Not every section of road has the same characteristics or presents the same potential consequences.

Installation is particularly important in the following locations:

  • Tight bends or sections with pronounced changes in alignment.
  • Sections with a history of motorcycle collisions.
  • Secondary roads frequently used by motorcyclists.
  • Areas with changes in level, embankments or rigid obstacles.
  • Interchanges, slip roads, merging lanes and exits.
  • Sections where a loss of control could lead directly towards a barrier.

Secondary roads require particular attention because they often combine successive bends, narrow hard strips or verges, accesses, junctions and roadside objects close to the carriageway. These roads are also frequently used by motorcyclists, particularly at weekends and during leisure periods.

4. Continuity, terminals and transitions

The effectiveness of a restraint system does not depend solely on the central section of the barrier. Its ends, connections and transitions can also become critical points.

Barrier end terminals must prevent the beginning or end of the system from becoming a rigid obstacle during an impact. These devices are designed for installation at the ends of safety barriers and absorb part of the energy generated in a collision.

Similarly, transitions between restraint systems connect barriers or parapets from different product families or with different containment levels while maintaining an appropriate change in stiffness.

Projects intended to improve motorcyclist safety should assess the following elements together:

  • The main safety barrier.
  • The Motorcycle Protection System.
  • The approach and departure terminals.
  • The transitions between different systems.
  • Roadside obstacles and changes in level.
  • The space available for the system to deform.

A partial or incorrectly installed system may simply transfer the risk from one point to another. Protection must therefore remain continuous throughout the entire potential impact area.

The importance of addressing these points correctly is also discussed in the article about changes to the regulations governing safety barrier transitions and terminals.

5. Design, installation and maintenance

The performance of an MPS also depends on whether it is installed in accordance with the manufacturer’s specifications. Changes to its height, anchors, post spacing or connections may alter the response of the complete system during a collision.

Subsequent maintenance is equally important. Impacts, corrosion, unsuitable repairs or changes in ground level can reduce the effectiveness of the system.

Inspections should assess the condition of the rails, posts, bolts, anchors, terminals and transitions. They should also identify deformation, incompatible components or accumulations of soil and vegetation that could affect the device’s effective height.

6. Roads that are more forgiving of human error

Analysis of motorcycle collisions makes it possible to identify risk patterns and apply more effective measures. In run-off-road collisions, Motorcycle Protection Systems play an essential role in reducing the consequences of an impact against a steel safety barrier.

The objective is not simply to prevent the vehicle from leaving the carriageway. The infrastructure must also be prepared to protect the motorcyclist after a fall and prevent the restraint system itself from making the resulting injuries more severe.

At Metalesa, we design and manufacture road restraint systems adapted to the characteristics of each road. The use of MPS, safe terminals and properly designed transitions contributes to more forgiving roads that can reduce the severity of an accident when human error cannot be prevented.

by javier

ITS could reduce serious run-off-road collisions by 60%

Run-off-road collisions are among the most serious types of accident on interurban roads. They occur when the driver loses control and the vehicle leaves its intended path, potentially colliding with changes in level, obstacles, structures or other objects located along the roadside.

A study carried out by Metalesa in collaboration with the University Research Institute on Traffic and Road Safety — INTRAS — at the Universitat de València has analysed the relationship between these accidents and Intelligent Transport Systems.

Its main conclusion is particularly significant: the ITS analysed could intervene in circumstances present in 49.5% of all run-off-road collisions. When the analysis is limited to serious and fatal accidents, the percentage rises to 59.7%.

This finding positions technology applied to infrastructure as a complement to conventional restraint systems.

A study based on interurban road accidents

The study analyses data recorded between 2017 and 2023 in the Spanish Directorate-General for Traffic’s ARENA system. Its methodology relates the circumstances recorded in accident reports to the systems included in the DGT’s ITS Plan.

The purpose is not simply to count accidents, but to determine which technologies can address the factors that occur most frequently or produce the most serious consequences.

Three criteria are used to establish these priorities:

  • Accident frequency: the number of accidents.
  • Injury severity: the number of casualties and the severity of their injuries.
  • Fatality rate: the proportion of people killed.

More than 37,000 accidents occur on interurban roads in Spain each year. Approximately 12,000 are run-off-road collisions, resulting in close to 500 deaths annually according to the data included in the study.

How can ITS respond to a run-off-road collision?

Intelligent Transport Systems combine sensors, radar, communication systems and signalling devices to detect risks and generate a response from the infrastructure itself.

Their role can begin before the vehicle leaves the carriageway. A system can, for example, detect inappropriate speed, adverse weather conditions or failure to maintain a safe following distance and activate a warning for the driver.

The technologies studied include:

  • Dynamic adaptation of speed limits.
  • Spot speed enforcement using fixed cameras.
  • Average-speed enforcement using section cameras.
  • Speed-limit violation warning systems.
  • Traffic guidance during adverse weather conditions.
  • Seat belt use detection.
  • Warnings when a safe following distance is not maintained.
  • Detection of animals or vulnerable road users on the carriageway.

These solutions do not all perform the same function. Some seek to prevent loss of control, while others reduce the severity of injuries or allow an impact to be reported quickly.

Speed as one of the main areas for intervention

Speed has a significant relationship with run-off-road collisions. The study indicates that, among accidents associated with the dynamic adaptation of speed limits because of adverse weather conditions, 66.5% were run-off-road collisions.

A strong relationship was also identified with speed-control systems using fixed cameras, average-speed cameras and speed-limit violation warnings. In these cases, run-off-road collisions accounted for 63.8% of accidents.

Dynamic adaptation makes it possible to change or reinforce the displayed limit according to the actual conditions on a section of road. It can be activated, for example, during heavy rain, fog or strong winds, or whenever the prevailing speed is unsuitable for the conditions.

Road signs therefore cease to provide a static message and instead respond to the specific condition of the road.

Seat belt detection and reducing accident severity

Not every ITS intervenes directly before a vehicle leaves the road. Some are intended to reduce the severity of the consequences.

The study analysed 34,613 accidents recorded between 2017 and 2023 in which a seat belt had not been worn. These accidents resulted in 48,388 casualties, including 2,982 fatalities and 8,593 people seriously injured.

In addition, 36.7% of the accidents associated with failure to wear a seat belt were run-off-road collisions.

Detection systems can identify non-compliance and generate a warning. In an accident, the seat belt remains essential for preventing occupants from striking the vehicle interior or being ejected.

From a conventional barrier to connected infrastructure

Prevention through ITS does not replace safety barriers, bridge parapets, terminals or crash cushions. These two levels of protection perform different but complementary functions.

Intelligent systems act before an accident by detecting and signalling the risk. Road restraint systems intervene once the vehicle has lost control, seeking to contain it, redirect it or reduce the energy of the impact.

Integrating both functions allows conventional equipment to become part of connected infrastructure. Sensors, radar and cameras can detect a dangerous situation, while road studs or variable-message signs communicate the warning to the driver. Data can also be sent to road operators, control centres or emergency services.

PLUG&META®: sensing and signalling from road equipment

PLUG&META® technology integrated into PlugSmart® Pro can transform restraint systems and other roadside equipment into intelligent devices.

The system can be installed on steel safety barriers, bridge parapets, concrete barriers, walls or tunnel linings. It operates through connections with radar, cameras, weather sensors and dynamic signalling equipment.

Situations it can detect or signal include:

  • Vehicles travelling at excessive speed.
  • Vehicles involved in accidents or breakdowns.
  • Wrong-way driving.
  • The presence of pedestrians, cyclists or animals.
  • Ice or reduced visibility.
  • Impacts against the restraint system.

When a risk is detected, the infrastructure can activate a light signal to warn approaching vehicles. If the accident cannot be prevented, the system can report the impact to the operator and send information to traffic platforms or control centres.

Prioritising ITS according to the risk on each road section

The study proposes a methodology for selecting ITS according to the accident frequency, injury severity and fatality rate associated with each circumstance.

This means implementation should not be treated as a uniform solution for the entire network. A section with run-off-road collisions linked to speed and weather conditions may require dynamic speed-limit adaptation and illuminated warnings. Another section with frequent wildlife activity may require specific sensors and alert systems.

Data analysis can identify which technology best responds to each scenario and concentrate action on the highest-risk locations.

Active road safety and vehicle restraint must work together

The figure of 59.7% represents the potential scope for ITS intervention in circumstances associated with serious and fatal run-off-road collisions. It does not mean that a single technology could automatically prevent all those accidents. It indicates that detection, warnings or control could perform a preventive role in a significant proportion of cases.

Combining ITS equipment and road restraint systems makes it possible to act at different stages:

  • Detect the risk in advance.
  • Warn the driver.
  • Adapt the signs or speed.
  • Contain the vehicle if it leaves the carriageway.
  • Detect the impact and report the incident.

Metalesa develops restraint systems and connected-infrastructure solutions designed to integrate these functions. The objective is to progress from a road that only responds to an impact towards one capable of detecting risk, communicating it and helping to prevent the accident.

by Metalesa

Connected Crash Cushions: The next step towards the Smart Road

The evolution towards connected mobility is transforming the landscape of our roads. Passive safety elements, traditionally static, are giving way to a new generation of ITS Equipment (Intelligent Transport Systems). In this context, connected crash cushions represent an exciting breakthrough: they convert a vital containment device into a real-time communication node.

This technology merges the mechanical performance of cushions with the potential of IoT, creating a system that not only protects lives during impact but also accelerates medical response and incident management.

The Foundation: Safe, effective, competitive, and easy-to-adapt equipment

For a crash cushions to be "intelligent", it must first prove its mechanical performance according to current regulations. Connectivity is meaningless if the device does not guarantee maximum kinetic energy absorption.

The Metalesa range of impact attenuators offers excellent physical performance. Entirely designed in galvanised steel to maximise durability and recyclability, they strictly comply with the UNE EN 1317-3 standard. Their modular design covers all the needs of modern roads:

  • Speed Versatility: Certified configurations for 50, 80, 100, and 110 km/h levels.

  • Redirective Typology: Unlike older systems, this range is redirective (R). This means that, in the event of a side-on collision, the attenuator not only absorbs the shock but also guides the vehicle back onto the carriageway in a controlled manner, preventing it from entering hazard zones or falling down embankments.

  • Geometric Adaptability: The range includes Parallel models (ideal for tunnels and constant central reserves) and Trapezoidal (Wide or Semi-Wide) models, designed to protect junctions and wide obstacles where the risk of impact is higher.

The latent problem: The "Golden Hour" and secondary accidents

Even with the safest cushions on the market, reaction time after an accident remains a critical factor. Data from bodies such as the FHWA reveal that for every minute a lane remains obstructed, the probability of a secondary accident increases by 2.8%. Furthermore, reducing medical response time by 1 minute increases the victim's survival chances by up to 6%.

This is where smart crash cushions technology makes the difference, eliminating dependence on manual or chance warnings.

Integrated Intelligence: PLUG&META® connectivity

The innovation lies in providing this robust steel structure with a "digital layer" that elevates this equipment to the advanced level of active road safety, accident prevention, and notification. Thanks to Plug&Meta® technology, Metalesa’s range of cushions is "connection-ready". Integrated sensors monitor the device without altering its mechanical properties or certification.

The system's operation closes the safety cycle in three phases:

  1. Detection and Signalling: Sensors detect the impact and activate integrated light beacons to alert oncoming drivers. Remote vertical signs located before the impact point can also be triggered.

  2. IoT Transmission: The system sends an immediate geolocated alert via NB-IoT or 4G/5G networks to the control centre, DGT 3.0, or other data platforms.

  3. Management: Emergency services and road operators receive real-time notification of the incident with the precise location of the impacted cushions, allowing for immediate deployment of traffic assistance and medical care.

Operational efficiency and maintenance

Beyond emergencies, digitalisation offers tangible economic advantages. Remote management allows for preventive maintenance based on the actual condition of the equipment.

It is estimated that remote monitoring can reduce operational maintenance costs by up to 20%. Instead of sending patrols to visually check the state of cushions on distant motorways, the manager knows at all times whether the device is operational or if it has suffered a minor impact requiring repair, thus optimising conservation resources.

Physical and digital safety

Metalesa’s strategy demonstrates that modern road safety is an inseparable pairing. On one hand, a cutting-edge physical structure—impact cushions certified under the UNE EN 1317-3 standard—and on the other, an IoT intelligence layer connecting infrastructure with managers. This integral approach not only protects vehicle occupants during a crash but ensures immediate care afterwards, defining the new standard for active road safety in the era of Smart Roads.

by César Valero

Fall protection: Road and urban railing, fencing and enclosures for height safety in public spaces

When we talk about infrastructure safety, the focus is often exclusively on the road. However, pedestrian safety in public spaces, stadiums, transport stations, and industrial zones represents an equally critical challenge. In this context, passive fall protection stands as the first and most effective line of defence to guarantee the physical integrity of individuals.

Unlike active protection (such as harnesses or lifelines, which require training and action from the user), passive systems protect permanently and autonomously, eliminating the human error factor. This article analyses why safety railings and technical enclosures are a mandatory investment—not only ethically but regulatorily.

The Magnitude of the Risk: Data and Statistics

Falls from height are not isolated incidents. According to World Health Organization (WHO) data, falls are the second leading cause of accidental injury deaths worldwide.

In the field of infrastructure and public assembly spaces, statistics reinforce the need for robust systems:

  • The Human Factor: It is estimated that 85-90% of accidents at height are influenced by human error or distraction. This is the core advantage of passive fall protection: it works independently of the user's attention.

  • Accident Costs: A report by the European Agency for Safety and Health at Work indicates that costs resulting from accidents due to a lack of safety measures can amount to 4% of annual GDP in economic losses, including sick leave, compensation, and healthcare costs.

Regulatory framework: Space safety regulations and thrust loads

The installation of safety railings in public spaces is not an aesthetic matter, but one of regulated structural engineering. In many regions, rigorous requirements are established for public assembly spaces like sports stadiums, concerts, or train stations; railings must withstand much higher horizontal loads than in residential settings:

  • Crowded Areas: Regulations often require railings in stadiums or high-traffic areas to resist a horizontal force of 3.0 kN/m (kiloNewtons per metre).

  • Anti-climb Design: Regulations explicitly prohibit designs with horizontal rails that allow climbing in areas frequented by children, requiring the use of vertical bars or solid panels.

Technical solutions: Road and urban railing and road and urban fences

To mitigate these risks, solutions must adapt to the specific environment:

  • Road and Urban Railing (for Viaducts and Urban Use):

    These are critical elements on pedestrian bridges, promenades, or urban gradients. They must combine extreme mechanical resistance with high-durability anti-corrosion treatments (such as hot-dip galvanising according to ISO 1461). Their function is twofold: to prevent accidental pedestrian falls and, in many cases, to contain the impact of cyclists or Personal Mobility Vehicles (PMVs).

  • Road and Urban Fences (Perimeter Safety):

    Beyond falls, the risk in railway or industrial infrastructure is intrusion. Perimeter fences act as both a deterrent and a physical barrier. In Occupational Risk Prevention (ORP) environments, these systems are vital for segregating safe walkways from areas with moving machinery or electrical risks. Within this category, anti-suicide fences are particularly relevant, specifically designed to prevent scaling at critical high points.

An Integral approach to safety

The implementation of collective protection systems offers a direct return. Comparatively, although the initial investment in passive systems (fixed railings) may be higher than temporary solutions, their operating cost is near zero throughout their useful life.

Furthermore, in the field of infrastructure maintenance, these elements are key to Occupational Health and Safety (OHS). They ensure that cleaning, lighting maintenance, or gardening staff can carry out their tasks in elevated environments (such as technical roofs or embankments) without the need for complex Personal Protective Equipment (PPE), thereby speeding up work times and reducing workplace accidents.

Safety at height in public spaces leaves no room for improvisation. Passive fall protection through certified safety railings and robust perimeter fences is the only guarantee of regulatory compliance and real public protection. For architects, construction companies, and administrations, having manufacturers who understand the engineering behind every tube and anchor is the first step toward building safe and responsible urban environments.

by Sheyla Teherán

The data generated by the road: Intelligence applied to road safety and maintenance

The road is no longer a passive and static infrastructure but has become a dynamic, information-generating environment. In the era of connected mobility, the efficient management of the Spanish road network no longer depends solely on construction machinery, but on the ability to capture, process, and act upon information in real-time.

This digital transformation is key to the optimisation of resources by public administrations. Moving from a reactive model to a data-driven one allows for maximum road availability and guarantees safety with unprecedented budgetary efficiency.

From physical to digital infrastructure: Capture technology

The first step in this revolution is sensorisation. However, the historical challenge has been how to integrate delicate technology into the harsh road environment without compromising the structure. The industry's answer has been to develop specific connection systems that transform passive equipment into intelligent digital supports.

A key example is PLUG&META® technology, a universal connection interface designed by Metalesa that integrates into containment systems or metal supports. This innovation allows electronic devices to be installed in a simple and modular way, turning a barrier or other road safety equipment into an intelligent connection point without altering its mechanical properties or its safety certification.

Thanks to this integration capability, it is possible to collect massive amounts of data using advanced solutions such as PlugSmart® Pro. This proactive road safety device is specifically designed to detect critical variables that directly affect accident rates, such as:

  • Detection of accidents and obstacles on the carriageway.
  • Identification of wrong-way vehicles and excessive speeds.
  • Presence of wildlife or vulnerable users on the road.
  • Monitoring of adverse weather conditions (ice, fog, reduced visibility).

The brains of management: Big Data applied to mobility

The collection of information on risks and events feeds what we know as road Big Data. Through advanced algorithms and integrated management platforms, infrastructure managers can cross-reference these heterogeneous variables to obtain a holistic view of the road.

The implementation of PlugSmart® Pro allows for the collection of risk and event data to improve mobility management and make signalling decisions that reduce accidents. This device not only "listens" to the road but interacts with it: thanks to its controlled LED lighting system, it issues automatic visual warnings to users based on detected risk events (for example, activating light alerts in the presence of an animal on the road or a drastic reduction in visibility due to fog).

Towards predictive and efficient road maintenance

Beyond immediate safety, the use of IoT technologies and Big Data allows for substantial progress in the daily operations of roads. By having a constant data network on what is happening in the infrastructure, maintenance strategies evolve towards efficiency:

  • Data-driven planning: The analysis of flows and events allows for the detection of sections with greater wear or structural risk, enabling maintenance investments to be strategically directed to where they are most needed.
  • Resource optimisation: Remote monitoring reveals the condition of the equipment without the need for constant dispatching of operators, which drastically reduces operational costs and budgetary waste.

It is important to clarify that, whilst devices such as PlugSmart® Pro focus on road safety and accident prevention, it is the overall digital infrastructure (enabled by interfaces like PLUG&META®) that sustains long-term predictive maintenance.

The integration of ITS solutions and Big Data into road safety equipment represents the present of infrastructures. By leveraging the data generated by the road, administrations can guarantee safer and more technologically advanced routes. The commitment to digitalisation not only saves lives through active prevention but also ensures much more efficient and sustainable management of public assets.

by César Valero

The Importance of Preventive Maintenance in Road Safety: Prolonging the lifespan of infrastructures

Transport infrastructure management has undergone a paradigm shift over the last decade. Faced with the need to optimise public budgets and guarantee high protection standards, preventive road maintenance is no longer an option but has become the most efficient strategy.

This methodology does not view conservation as an operating expense, but as a financial investment that maximises the return on the initial construction. The data is conclusive: waiting for the functional failure of the road is neither economically nor socially sustainable.

Economic efficiency: The 1:5 Rule

The strongest argument for public institutions is profitability. In infrastructure engineering, the so-called "Law of De Sitter" applies, which establishes a geometric progression in intervention costs.

According to this principle, every euro not invested in preventive maintenance (when the defect is incipient) turns into 5 euros of expenditure when the damage requires minor correction, and skyrockets to 25 euros when full rehabilitation is necessary. Applying preventive strategies—such as checking the tightening torque on barriers or the early sealing of cracks—allows this escalation of costs to be avoided, freeing up resources that would otherwise be absorbed by emergency repairs.

Operational impact: Cost reduction for the user

The condition of the road has a direct impact on citizens' pockets and the competitiveness of businesses. According to the latest Audit by the Spanish Road Association (AEC 2025), the maintenance deficit (estimated at over 13.4 billion euros) generates tangible inefficiencies:

  • Additional fuel costs: A poorly maintained pavement and infrastructure increase rolling resistance, raising fuel consumption by up to 12%. It is estimated that this factor generates an annual extra cost of over 270 million euros in the months of highest mobility alone.
  • Carbon Footprint: This increase in consumption implies a proportional increase in emissions. Sector studies calculate that poor maintenance has caused the extra emission of more than 25 million tonnes of CO2 over the last decade.

Road maintenance and containment systems

Within road equipment, containment systems (metal barriers and parapets) are critical elements whose degradation can be "silent". Unlike a pothole, which is obvious, a barrier with internal corrosion or weakened anchorages may appear functional until it fails upon impact.

Proper preventive road maintenance of these elements includes verifying the tension of the beams, the condition of the spacers, and the integrity of the galvanisation. Bearing in mind that network deterioration advances at a rate of 8% annually, implementing periodic inspection programmes is the only way to ensure that these systems comply with the containment levels (N2, H1, etc.) certified under the UNE EN 1317 standard throughout their useful life.

The key to infrastructure durability

The sustainability of public works depends on how long they can operate without being rebuilt. International studies (Kahn & Levinson) suggest that every dollar allocated to prevention saves between 4 and 10 dollars in future reconstruction costs.

In the case of metallic safety elements, preventive maintenance acts directly on the product's life cycle. Detecting and treating areas of premature oxidation in saline environments or repairing minor deformations prevents the complete replacement of barrier sections, drastically reducing raw material consumption and the energy associated with manufacturing new steel.

The role of advanced technical inspection

To execute this strategy, the fundamental tool is data-driven road inspection. With 52% of the Spanish network showing significant deterioration, the use of high-performance technologies allows the condition of thousands of kilometres to be audited in reduced times.

However, inspection is only the first step. The true value lies in how that information is integrated into an intelligent management cycle.

Technology: The engine of planning and control

Today, the modernisation of road maintenance necessarily requires digitalisation. Technology is not an accessory, but the axis that allows us to plan, execute, and control the condition of our roads with surgical precision:

  • Digital Twins: Creating virtual replicas of the infrastructure makes it possible to simulate the ageing of materials and predict when a containment system will fail before it happens, optimising replacement cycles.
  • Computer Vision and AI: Using high-resolution cameras combined with deep learning algorithms automatically identifies cracks, oxidation, or loose bolting through image processing, eliminating human error in inspections.
  • IoT and Structural Monitoring: Connected sensors on critical bridges and barriers report impacts, anomalous vibrations, or structural tensions in real-time, allowing for an immediate response and comprehensive inventory control.
  • Cloud Management Platforms: Centralising data gives public administrations total control over maintenance contracts, verifying that preventive tasks are carried out on time and as planned.

Opting for preventive road maintenance is a strategic decision that benefits both the manager and the user. Nevertheless, in the current scenario, this model is only viable through the adoption of cutting-edge technological solutions. The combination of accurate data and intelligent management tools is the only way to maximise public budgets, prolong the lifespan of infrastructures, and, above all, guarantee that the road is always a safe and efficient environment.

by Sheyla Teherán

Hot-dip galvanizing: Durability of road safety equipment

Road safety depends on the structural integrity of its devices. From vehicle restraint systems (safety barriers, guardrails, impact attenuators, etc.) to sign gantries and road markings, most of these systems are made of steel. The greatest enemy of steel, especially in environments exposed to the elements and corrosive agents (salt, humidity, pollution), is corrosion. While other solutions such as weathering steel are beginning to be explored, hot-dip galvanizing is undoubtedly the leading solution that guarantees the longevity and consistent performance of the equipment, directly impacting the reduction of maintenance costs for public administrations.

1. Corrosion: The Hidden Cost on Roads

The oxidation of steel is not just an aesthetic problem; it compromises the functional capacity of road equipment. For example, a corroded guardrail can fail to absorb the energy of an impact, endangering the lives of vehicle occupants.

The costs associated with corrosion are divided into two categories:

  1. Direct maintenance costs: Repair or premature replacement of corroded components, including the cost of personnel, materials, and traffic management during the intervention.
  2. Indirect safety costs: The risk of equipment failure and the potential increase in accidents if the device does not perform its function.

2. The Hot-Dip Galvanizing Process

Discontinuous hot-dip galvanizing is a metallurgical process in which steel is immersed in a bath of molten zinc at a controlled temperature between 440°C and 500°C. This process not only coats the surface of the steel but also creates an iron-zinc intermetallic alloy metallurgically bonded to the base steel. For this reason, the final result is considered more of an alloy than a simple surface coating.

2.1 Process Phases for Durable Coating

To ensure proper adhesion of the alloy layers, the process follows a strict 10-step sequence before immersion in the zinc bath:

  1. Receiving and Shipping: Initial inspection of the parts and preparation for the process.
  2. Acid Degreasing: Removal of grease, oil, and surface dirt using degreasing solutions.
  3. Pickling: Immersion in acid (generally hydrochloric acid) to remove rust and mill scale, leaving the steel chemically clean.
  4. Washing: Rinsing to remove surface acid residue before the next phase.
  5. Fluxing: Immersion in a zinc ammonium chloride solution to prevent premature oxidation of the clean steel and facilitate the metallurgical reaction with the molten zinc.
  6. Oven Drying: Complete removal of moisture from the fluxed parts to prevent violent splashing upon contact with the molten zinc.
  7. Furnace Drying: Complete removal of moisture from the fluxed parts to prevent violent splashing upon contact with the molten zinc. Galvanizing: Immersion in a molten zinc bath, where the Fe-Zn alloying reaction occurs.
  8. Air Cooling: Controlled removal from the zinc bath to allow the coating to solidify and cool.
  9. Optional Passivation: Post-galvanizing chemical treatment to minimize the formation of "white spots" during storage.
  10. Refinishing and Shipping: Removal of excess zinc, final thickness inspection according to regulations, and preparation for shipment.

2.2 Protection Mechanisms

Unlike paints or surface coatings, hot-dip galvanizing offers a double layer of protection:

  • Physical Barrier: The zinc coating isolates the steel from the corrosive environment (humidity, oxygen, salt).
  • Cathodic Protection (Sacrificial): If the zinc layer is damaged (for example, by scratching or impact), the zinc, being more reactive than iron, is sacrificed and corrodes first. This protects the underlying steel from oxidation by healing small damaged areas (the so-called "galvanic cell").

This sacrificial protection is critical for road safety elements that are constantly exposed to abrasion and minor impacts.

3. Durability and Reduced Life Cycle Cost

The main advantage of hot-dip galvanizing is its exceptional durability, especially compared to other protection methods (paints or electrolytic zinc coatings).

Hot-dip galvanizing provides, with a single application, protection that can last for more than 50 years in most road environments, resulting in a lower Life Cycle Cost (LCC) for the administration.

3.1 Cost Comparison

The initial cost of a hot-dip galvanized element may be slightly higher than painting, but the need for maintenance is eliminated for decades. If projected over 50 years, the total cost of a painted component (requiring 5-10 repaintings) is up to four times higher than the single cost of the initial galvanizing investment.

4. Regulatory Compliance and Quality Assurance

The effectiveness and reliability of hot-dip galvanizing are regulated by international and European standards that guarantee the performance of products in road infrastructure.

  • ISO 1461 / EN ISO 1461: This standard specifies the properties of hot-dip zinc coatings on finished products (including fasteners and road safety components). It establishes the minimum coating thickness requirements, measured in microns (µm), which depend on the thickness of the base steel.
  • Visual Finishes and Quality: It is important to note that the final appearance of the galvanized coating may vary (high gloss, crystalline, matte gray). These different shades are characteristic of the process and depend on the chemical composition and reactivity of the steel, as well as the cooling rate. These color variations should not be considered defects, as corrosion resistance remains unchanged. Natural aging over time will homogenize the color.
  • CE Marking: In the European Union, road safety devices (such as barriers) must bear the CE marking, which signifies that their manufacture, including anti-corrosion treatment, complies with European performance and durability standards.

By specifying hot-dip galvanizing, authorities not only purchase durability but also ensure compliance with strict safety regulations. Infrastructure protected with this method extends its lifespan, improves safety, and allows managing bodies to redirect resources from corrective maintenance to more strategic investments.

by Sheyla Teherán

Energy Efficiency in Lighting: The strategy of the State Road Network (RCE)

The State Road Network (RCE), managed by the Directorate-General for Roads (DGC) of the Ministry of Transport and Sustainable Mobility (MITMA), faces an energy challenge of great magnitude. The energy efficiency strategy has become a priority to reduce high operating expenditure and align with the objectives of the ecological transition, based on technological modernization and advanced telemanagement.

1. Context and Magnitude of Energy Expenditure

The RCE's electricity consumption is one of the largest in public administration. Historically, consumption has remained close to 145,000,000 kWh/year, with an associated cost of tens of millions of euros, underscoring the urgency of intervention.

1.1 Critical Distribution of Consumption

The interurban infrastructure shows an unbalanced consumption distribution, primarily concentrated in the lighting and operation of enclosed structures.

This dependence on consumption in tunnels (where lighting and ventilation are vital safety functions that cannot be interrupted) demands solutions of maximum efficiency that do not compromise visibility standards.

2. The Innovation Strategy (CPI) and the Three Lines of Action

The RCE's strategy is articulated around Public Procurement of Innovation (CPI), a mechanism used by MITMA to promote technological solutions addressing its specific needs.

The central goal of the DGC is to achieve savings of between 40% and 50% of the network's total consumption. This is achieved through coordinated action in three fundamental lines of action:

Axis 1: Luminaire Requirements (LED Migration)

The migration from obsolete technologies like high-pressure sodium lamps (VSAP) to LED technology is the first step, but it must meet advanced technical requirements to ensure long-term durability and efficiency in a demanding environment:

  • Required Service Life: New luminaires are required to have a very high minimum service life, with certifications such as L90B10_100.000h. This means that only 10% of the units can have depreciated their luminous flux below 90% of their initial value after 100,000 hours of operation.
  • Maintenance Reduction: High reliability is key to minimising interventions on the road, which are costly and dangerous.

Axis 2: Telemanagement and Dynamic Control (ITS)

The implementation of an Intelligent Management System (SGI) is essential to achieve savings targets through dynamic light adaptation.

  • Standard Connectivity: The control nodes that allow remote monitoring and dynamic adaptation must be of an international standard, integrated using NEMA or Zhaga connectors.
  • ITS Functionality: The SGI enables the dynamic adaptation of lighting in real-time to environmental and traffic conditions. During off-peak hours, intensity is reduced to pre-established levels, but the system must be capable of immediate re-activation when vehicles pass or in emergency situations (e.g., an accident warning or fog).

Descriptive Chart: RCE Saving Goal

  • Baseline Consumption (Without CPI): 145.000.000 kWh/year
  • Saving Target (40%): Reduction of 58.000.000 kWh/year
  • Target Consumption: 87.000.000 kWh/year.

Axis 3: Road Safety and Strict Regulatory Compliance

On roads, lighting is a safety factor that must be managed with millimetre precision, especially at high speed. Therefore, regulatory compliance is non-negotiable and becomes the third strategic pillar:

  • Luminance vs. Illuminance: Unlike urban roads (where illuminance is measured), on highways, average luminance (Lm) is prioritised, which is the light reflected from the pavement to the driver's eye.
  • Requirement Levels: Lighting solutions must guarantee the average luminance levels required by regulations, which range between 0.30 and 2.00 cd/m², depending on the type of road (motorway, conventional) and traffic intensity (IMD).
  • Mitigation of Accident Risk: Efficient and reliable management of lighting at singular points is an unavoidable road safety priority. Studies like the one by INTRAS on run-off-road accidents have shown that the lack of lighting is a factor that significantly increases the risk and percentage of night-time accidents, justifying investment in intelligent and reliable systems at points where lighting is legally mandated.

3. Vision 2030: Digital Transformation and Sustainability

Smart road lighting in the RCE is not just a saving measure but a strategic component of the road network's transformation:

  • Sustainability: Energy saving contributes directly to the objectives of the RCE's 2030 Energy Efficiency Strategy, minimising energy dependence and reducing the infrastructure's carbon footprint.
  • Big Data and ITS Integration: The lighting telemanagement nodes are transformed into a sensor network that can be integrated into the MITMA ITS ecosystem. This allows for the collection of environmental and traffic data at remote points, crucial for predictive infrastructure maintenance and informed decision-making in mobility planning.

In summary, the investment in adaptive lighting for the RCE represents a paradigm shift: from being merely an operating cost, lighting becomes an intelligent management asset that guarantees maximum safety and regulatory compliance with the minimum energy footprint.

by César Valero

Infrastructure management: The challenge of the maintenance backlog and the importance of asset inventory

Road maintenance is a fundamental pillar for ensuring mobility and user safety. However, the sector faces a structural challenge: managing assets that, due to an accumulated investment backlog, require immediate intervention.

Beyond theoretical debates, the operational reality shows that current management must focus on correcting incidents to ensure infrastructure quality. According to the recent Audit by the AEC (Spanish Road Association), the deterioration of functional elements forces a prioritisation of asset repair and replacement to guarantee functionality and extend the product lifecycle.

Below, we analyse the current state of the network and how technology and compliance with road safety regulations are key to recovery.

1. Situation analysis: Impact on road maintenance costs

Technical data reveals a complex scenario. The investment deficit has led to the accelerated ageing of deployed equipment. From a technical perspective, this implies that a large part of the infrastructure has exceeded its optimal service life and cannot be expected to operate with the foreseen performance levels.

Sector studies indicate that postponing corrective intervention multiplies future costs and affects road sustainability. A road without adequate asphalt is not only unsafe but also increases vehicle fuel consumption, raising the infrastructure's carbon footprint. A road with defective road markings and deteriorated vertical signage harms road safety. A road whose restraint systems are obsolete and in poor condition is less prepared to be a "forgiving road".

2. The foundation of efficient management: Inventory and road inspection

In an environment of limited resources, a comprehensive inventory is indispensable. It is not viable to plan without precise knowledge of the installed reality. The trend towards Smart Roads begins by digitising the basics:

  • Georeferencing: Exact location of each asset.

  • Diagnosis: Classifying elements according to their degree of deterioration.

  • Data: Utilising road Big Data to prioritise actions based on technical risk.

3. Critical areas for technical intervention

Safety depends on the correct interaction of all elements. The deficiencies detected require specific actions in four main blocks, always complying with road product certification:

3.1. Pavements and road surfacing The road surface is the element most exposed to wear. A degraded pavement reduces skid resistance and increases the risk of accidents. Its repair is a priority to restore safety and transport efficiency.

3.2. Vertical signage and active road safety Signage has a limited service life. Compliance with night-time visibility regulations is critical. Replacement must ensure the required levels of retroreflectivity, guaranteeing that signs are visible and legible in any condition, acting as true active infrastructure.

3.3. Road markings (horizontal signage) Road markings are fundamental for the human driver, especially on regional roads where there are often more bends and a lack of hard shoulders, vertical signage, or public lighting. Furthermore, even on high-intensity roads, they are fundamental for connected mobility. Driver assistance systems (ADAS) depend on well-painted and maintained lines to operate correctly.

3.4. Safety barriers and advanced restraint systems This is one of the most critical points. The current stock of metal barriers and guardrails presents significant challenges related to obsolescence, lack of performance, protection against corrosion, and damage from previous impacts. In this regard, and to guarantee safety, it is imperative that any replacement or new installation strictly complies with the EN 1317 standard. This implies using restraint devices that have passed the corresponding impact test, ensuring that their dynamic behaviour (working width and containment level) is appropriate for the type of road. Additionally, it is fundamental to consider the durability of metal structures through treatments such as galvanising to withstand weathering.

4. Technology and road sensorisation

The industry is advancing towards predictive maintenance solutions, such as the use of computer vision technologies (whether on-board a vehicle or from the air with drones) or LiDAR. These allow for road inspection at traffic speed, digitising the condition of equipment at very high speed, with maximum precision, and without risk to operatives.

These tools allow administrations to evolve towards more optimised asset and maintenance management, based on data and real-world diagnosis of deployed equipment, optimising every euro invested in road recovery.

Improving road safety requires facing the maintenance backlog with courage and new tools, ensuring that every euro invested is useful. Only in this way will it be possible to return the infrastructure to the quality standards that current mobility demands.

by César Valero