PlugSmart® Pro, Smart Road Safety Device Project

Initiative details

The stagnation of accident and mortality figures in Spain, particularly regarding run-off-road incidents, demonstrates that traditional road safety solutions, while still essential, have reached their maximum possible impact. Road network authorities must therefore immediately commit to new, disruptive, and innovative measures. An urgent response is required to make the European goal of Zero Victims by 2050 achievable, and this response must be supported by solutions that harness the potential of technology and artificial intelligence.
The main pain points are as follows:
1. High accident rate: Worrying levels of accidents, run-off-road incidents, and pedestrian collisions persist, resulting in severe human and economic consequences.
2. Reactive rather than preventive safety: Existing systems intervene only after an incident to minimise its consequences. There are very few real-time risk detection and alert mechanisms in place.
3. Lack of connected response: There are no infrastructure-based solutions capable of automatically detecting incidents or run-off-road events unless incorporated by the vehicle itself, which often leads to critical delays in notifying emergency services or alerting other road users.
4. Limited technological adaptability: Many roads lack basic supplies such as electricity or signal coverage for remote management.
5. Level of investment: While national authorities are progressively beginning to invest in advanced technological solutions, budgets remain limited, often restricted to pilot programmes and trials without genuine commitment. In numerous regional and local administrations, no officials have yet been appointed for road modernisation or digital transformation, and no budgets are allocated for these matters.
6. Digital technological expertise among road administrators: There is a clear shortage of technical profiles with expertise in IT or telecommunications, and public administrations are slow in equipping themselves with such profiles.
7. The challenge of intelligent infrastructure and the connected vehicle: There is an urgent need to seek alternatives to large-scale V2X (vehicle-to-everything) communication protocols between vehicles or between vehicles and infrastructure, as these may not prove effective in the short term due to factors such as public investment levels, the gradual renewal of the vehicle fleet, or the complexity of harmonising protocols across manufacturers and countries. Tactical solutions that demonstrate real, immediate impact are critically needed.
These are the principal pain points slowing the advancement of smart road deployment, understood as an entire ecosystem of connected, proactive, and preventive solutions to ensure safe, sustainable, and intelligent mobility.

Initiative date

Who was/is your target audience?

Public authorities
Car drivers
Car drivers – professional
Public transport
Van drivers
Lorry/truck drivers
Cyclists
Micromobility riders
Powered two wheeler riders (excluding micromobility)
Pedestrians

Topic

Improve vehicles and infrastructure
Knowledge building and sharing
Provide alternative solutions
Training

Organisation details

TECNOLOGÍA DE SEGURIDAD VIAL Y ACÚSTICA, S.L.
Enterprise
Spain
Carcaixent/Valencia

Contact name

José Carlos Cucarella

Telephone number

+34 651813249

Project activities

If you work together with external partners, list the most important partners and briefly describe their role.

Our external partners are briefly described below:

1. TECHNOLOGY PARTNER FOR INDUSTRIAL SOLUTIONS
A strategic partner specialised in the development of advanced technological solutions. Their collaboration encompasses overall consultancy on the technologies involved in the project, particularly the design, development, and manufacture of the solution’s core electronic systems, the governing firmware, and the communication protocols interconnecting all components. They also act as the liaison with other partners to integrate external peripherals such as sensors, cameras, or traffic signs.
Additionally, they design and implement the PLUG&META® TRACE management platform, which enables control, monitoring, and traceability of all deployed devices. This seamless hardware–software integration ensures the system’s reliability, scalability, and operational efficiency.

2. INSTITUTE OF AUTOMATICS AND INDUSTRIAL INFORMATICS (AI2), UPV: TECHNOLOGY PARTNER FOR FIRMWARE DEVELOPMENT
An original collaborator during the early phases of conceptualisation and development of the first technology prototypes. Their contribution focused on developing the programming for the system’s first functional firmware version, which served as the technological foundation for the subsequent evolution of the product.

3. RESEARCH INSTITUTE FOR TRAFFIC AND ROAD SAFETY
In collaboration with TSVA, this institute conducted a study on run-off-road accidents, focusing on the role of safety barriers in reducing accident rates, fatalities, and injury severity in urban and peri-urban areas, with particular attention to vulnerable road users. The study identified key risk factors associated with run-off-road incidents.

For the project’s development, the collaboration of several specialised supplier companies was also essential, responsible for providing and adapting key components and materials. The main collaborators in this area are detailed below:

4. ELECTRICAL COMPONENTS SUPPLIER
A comprehensive supplier of physical components and technical materials for the product. Responsible for providing housings, custom wiring, and the final enclosure of the device, ensuring compliance with requirements for durability, safety, and suitability for road environments.

5. ARTIFICIAL INTELLIGENCE SENSOR SUPPLIER
Provider of the external camera sensor with artificial intelligence for real-time event detection. In addition to supplying the hardware, they offer specialised technical support for integrating and calibrating the computer vision system within our solution.

6. SPEED DETECTION SENSOR SUPPLIER
A company specialised in the design and manufacture of radars for vehicle detection and speed monitoring. Their technology is a key element for collecting critical data in high-risk areas. They also provide technical support during the integration and deployment of these sensors within our intelligent solution.

7. ELECTRICAL COMPONENT ASSEMBLY SUPPLIER
Manufacturer of the electrical panels housing all the system’s electrical components. They assemble the necessary components into customised panels, designed according to our technical specifications to ensure safe and functional integration.

8. PHOTOVOLTAIC SOLUTIONS SUPPLIER
A specialist in the design and supply of photovoltaic systems adapted to the solution’s technical characteristics. Responsible for calculating the required autonomy, power, and capacity, as well as supplying all necessary materials, including batteries, solar panels, and associated components. Their contribution ensures full integration with our intelligent solution, providing flexibility and enhanced autonomy through solar-powered operation.

9. HIDDEN PANELS AND INFORMATION SIGNAGE SUPPLIER
A specialist in designing and manufacturing hidden panels and informative signage to maximise user understanding of the smart signalling system. They supply the necessary visual elements to ensure effective communication with road users, complying with visibility, regulatory, and durability requirements. They also tailor designs to the technical specifications of our intelligent solution, ensuring coherent and functional integration.

Although the current technology partners are fundamental to the project’s development and execution, TSVA’s strategic objective is to assume full control over all technological phases of the system. To this end, a structured knowledge transfer plan has been launched, progressively transitioning capabilities to our internal engineering team. This process not only guarantees the project’s long-term technological continuity and autonomy but also strengthens our internal capacities, optimises development timelines, and ensures the system’s continuous evolution from a fully integrated perspective — ultimately enhancing service quality.

Please describe the project activities you carried/are carrying out and the time period over which these were implemented.

The PlugSmart® Pro project was launched in 2020 with the aim of understanding, through rigorous scientific and technical analysis, the types, causes, and dynamics of run-off-road accidents in Spain. Over two years, a pioneering study laid the foundation for developing an effective technological solution.
In 2021, based on these findings, the first prototype was created for a Metalesa urban/peri-urban barrier. Between 2022 and 2023, the system was optimised: electronic components were improved, the casing redesigned, the firmware updated, and a user-friendly management platform developed. Functional and performance tests culminated in the first real-world pilot at the Bimilenario Bridge in Elche — the world’s first smart parapet, see more in:

https://www.youtube.com/watch?v=G8o7KRbwlI0

By 2024, the project shifted focus from a proprietary system for Metalesa barriers to a universal solution applicable across all types of road equipment, aiming to democratise active road safety worldwide.
In 2025, development continues, enhancing usability, integrating advanced sensors, AI, and cutting-edge communications. The first commercial deployments are underway internationally, including projects in Murcia (Spain) with the Ministry of Transport and Sustainable Mobility. These deployments will validate the technology in real conditions and assess its impact on accident rates and user perception — opening new research avenues to maximise both technological performance and societal acceptance.

In terms of implementation, what worked well and what challenges did you need to overcome?

TSVA was traditionally an engineering firm focused on structural design, with no prior experience in digital, sensor, signalling, IT, or communications solutions. The scale of the challenge is striking: over 95% of companies offering ITS solutions for smart roads come from the technology sector, not civil engineering. To fully appreciate TSVA’s achievement, it is worth noting that before this project, no one within the Metalesa Group had technological or IT expertise.
One of the first hurdles was conceptualising the solution, researching materials, and identifying and coordinating the right technology partners. TSVA set the technical and functional specifications, enabling its partner to develop the electronics, firmware, and management platform. This phase required major learning, particularly in electronics, systems integration, and hardware–software coordination.
TSVA also undertook the critical design of the system’s casing, achieving airtightness, mechanical strength, and durability for extreme weather. The device passed all required tests, achieving CE marking and meeting IP and IK certification standards.
A key success has been the strong industry response: PlugSmart® Pro is seen as an innovative, scalable solution with great potential to advance active road safety and infrastructure digitalisation.
Road authorities admit they know of no other market solution that can detect run-off-road incidents, send notifications, and offer such modular, scalable design for adding advanced safety features.
Surprisingly, even competing barrier manufacturers — aware of the complexity and years needed to develop such capabilities — are now approaching TSVA to secure distribution agreements in their regions.

Evaluation

Please summarise how you have evaluated the initiative’s impact (e.g. social media reach, survey, feedback forms, statistics).

The scientific and technical justification for ITS solutions has been established through the study “Prevention of Run-off-Road Accidents Using Intelligent Transport Systems (ITS)”, conducted by the Universitat de València in collaboration with TSVA. The study concludes that ITS solutions could prevent 49.5% of such accidents, rising to 59.7% for severe or fatal cases.
Regarding real-world impact, it is notable that 72.1% of these incidents are linked to speeding, highlighting the importance of dynamic speed adaptation technologies under changing visibility and weather conditions. In May 2025, a new comparative KPI measurement functionality was deployed to analyse speed variations when the system is active versus inactive. Data collection has recently begun in the Elche project; while conclusive results are not yet available, preliminary estimates suggest a 12.3% reduction in speed. The relationship between reduced average speed and accident ratios is not yet quantified but is likely significant. This same before-and-after assessment will be used in upcoming projects with the Ministry of Transport in Murcia.
Additionally, the Elche police control centre is directly connected to the system, receiving real-time alerts of barrier impacts and activating the relevant safety and medical protocols. TSVA has also conducted a user survey to assess social and human impact. Although still in the preliminary analysis phase, it can be concluded that 100% of pedestrians and 70% of drivers consider the solution highly positive for their safety.

What has been the effect of the activities?

The technology has been received with great expectation within the sector, generating notable interest for its validation and future deployment. It has been nationally recognised with the PONLE FRENO–AXA 2024 Road Safety Innovation Award and honoured at specialist congresses as a consolidated, high-potential project, attracting the attention of numerous companies seeking to complement their initiatives with cutting-edge solutions.
It has been implemented on the Bimilenario Bridge, the main traffic artery in the city of Elche, carrying an average daily volume of 25,000 vehicles. Here, the PLUG&META® technology monitors over 400 metres in each direction, significantly enhancing road safety along this strategic section.
An upcoming deployment will take place in the Region of Murcia, on the A-30 and A-7 motorways, which together handle over 315,000 vehicles daily — particularly at the critical Ronda Oeste junction, with a daily average of 112,000 vehicles. These figures represent the users who stand to benefit from the technology at identified high-risk sections.
As part of the project, the solution has been installed along over 600 metres of motorway ramps with dangerous curves, aiming to reduce accident rates by up to 59%, based on studies by the Universitat de València.
PlugSmart® Pro transforms any road equipment into an intelligent, autonomous system capable of detecting, notifying, and informing in real time — positioning itself as a key ally in advancing active road safety through its scalable, efficient, and adaptable technological ecosystem.

Please briefly explain why your initiative is a good example of improving road safety.

PlugSmart® Pro is a leading example of road safety innovation, as it addresses one of the most severe and frequent causes of road fatalities: run-off-road crashes, which account for over 33% of fatal incidents on interurban roads. This system transforms passive infrastructure—such as conventional roadside barriers—into intelligent, connected elements capable of detecting and responding to risk in real time.
Through the integration of advanced sensors, IoT connectivity, AI and adaptive lighting, PlugSmart® Pro continuously monitors the driving environment to identify potentially dangerous scenarios. These include vehicles travelling in the wrong direction, excessive speed, hazardous curves, presence of vulnerable road users, and adverse weather conditions. Upon detecting a risk, the system activates real-time visual alerts to inform drivers and prevent accidents. If a crash occurs, it automatically notifies emergency services—even if the driver is incapacitated—and signals other road users to prevent further collisions.
This initiative represents a model of best practice due to its holistic, scalable and field-tested approach. It not only enhances both active and passive safety, but also enables real-time data collection for authorities, improving road safety planning and evidence-based policy development.
PlugSmart® Pro is also highly transferable and easy to implement. Its technical features include rapid installation without specialised tools (thanks to an IP65-rated quick-connect system), a universal and modular design compatible with any barrier or roadside infrastructure, 24/7 operation with low energy consumption, and the option for photovoltaic power supply in remote locations. It can be remotely managed via the PLUG&META® TRACE platform, accessible from mobile devices, and integrates seamlessly with existing traffic management systems through open APIs. It also remains visible without power, due to its RA3 retroreflective panels.
Its adaptability, reliability and cost-effectiveness make it an accessible solution for public authorities and infrastructure operators across different contexts and countries. PlugSmart® Pro not only reduces crash rates and response times but also optimises infrastructure investment through predictive maintenance and improved situational awareness, setting a new standard for intelligent road safety systems.

How have you shared information about your project and its results?

The dissemination of the PlugSmart® Pro project has been carried out through:
1. Participation in Awards:
a) Ponle Freno-AXA Award for Innovation in Road Safety (winners 2024).
b) Revolution Awards BBVA (pending decision 2025).
c) ACEX National Award (finalists and pending decision 2025).
d) Spanish National Innovation Award (pending decision 2025).
e) Intertraffic Awards (under submission for 2025).
f) Excellence in Road Safety Awards (EU) (submitted for 2025).

2. Brand Initiative at exhibitions and conferences:
a) Selected by Mobility City Museum to be part of the exposition (2025).
b) Intertraffic Amsterdam (2022 and 2024).
c) AEC/ATC Conferences (2024 and 2025).
d) Universitat Politécnica de València Conferences (2024 and 2025).
e) Global Mobility Call (2024 and upcoming 2025 edition).
f) ITS Mobility City Ibercaja Forum (2025).
g) ATC Fair in Segovia (2025).
h) ITS Spain Congress (2025).
i) Koelnmesse Cologne exhibition center, Germany (2025).
j) ITS Europe Congress, Seville (2025).
k) SeguCITY Congress, Valladolid 2025.

3. With media coverage across press, specialized magazines, and TV, fueled by the widespread interest in the solution’s groundbreaking innovation
These actions have helped position the solution at the local, national, and international levels.