Reimagining rail electrification with composites
Steel has served rail electrification for over 60 years - but the demands of cost, carbon and installation safety have changed. Traditional cantilevers remain heavy, complex to install, and expensive to maintain. And while the rest of the network is evolving, this part of the system has largely stayed the same.
Furrer+Frey UK saw an opportunity to rethink it - and turned to NCC to help make it real.
Together, we developed and delivered I-CAGE (Innovative Cantilever for Greener Electrification) - a modular composite cantilever that is lighter, self-insulating, and designed for fast, low-impact installation.
From early design feasibility to full-scale prototype manufacture, NCC supported the technical development and helped build the case for adoption.
Engineering progress - from concept to proven solution
The first step was to prove it could work in practice - not just on paper.
NCC engineered and manufactured a fully functional composite cantilever, using a modular architecture of four injection-moulded components and interchangeable GFRP (glass fibre reinforced polymer) tubes. The system removed the need for separate insulators or metal fasteners, offering a cleaner, simpler structure that met installation and performance requirements.
But building a prototype wasn’t the end goal - deployment was.
We supported Furrer+Frey to evaluate production scalability, optimise the installation process, and assess long-term cost and carbon savings across the system’s lifecycle. The result - clear evidence that I-CAGE could deliver meaningful benefits at network scale.
The impact: cost, carbon, and confidence
Compared with traditional steel systems, the I-CAGE prototype delivered:
- 53% cost savings
- 64% reduction in structural mass
- 60% lower CO₂ footprint
- Reduced foundation depth
- Simpler logistics and installation
- Fewer people required on site
- No insulators, bolts or pins
These improvements aren’t hypothetical. They were achieved with a first-generation prototype - and further gains are possible through optimisation and industrialisation.
A new benchmark for future infrastructure
Electrification needs to accelerate, but upgrades must be smarter - not just more frequent. I-CAGE shows what’s possible when composites are applied with purpose: lighter structures, safer working conditions, lower whole-life costs, and a reduced carbon footprint.
It’s also a wider proof point - that with the right engineering support, novel concepts can cross the gap from innovation to infrastructure.
I-CAGE is more than a product - it’s a step towards modernising the way we electrify rail.