Norfolk Southern’s Engineering team successfully completed major infrastructure upgrades across two states in 30 hours in November, as part of the company’s $1 billion annual investment in its rail network. The simultaneous repairs at two critical sites in Illinois and Indiana underscore NS’ commitment to maintaining a safe, reliable, and resilient rail system.

“Our Engineering team demonstrated exceptional dedication and resilience to safely complete these projects in very challenging weather conditions. The entire Midwest Division Operations team and the Network Operations Center collaborated seamlessly to successfully complete these two critical projects with minimal impact to our customers,” said Ed Boyle, VP Engineering. “These projects not only strengthen our infrastructure but are also designed to provide long-term value and service reliability for many years to come.”

At the Decatur Terminal in central Illinois, the team worked during a 30-hour service outage to replace eight switches on the critical switching ladder at the west end of the westbound yard. These switches, equipped with power actuators controlled by yardmasters, are key to enabling more efficient switching operations. The job was in a physically challenging area with limited access to equipment and trucks. The Communication and Signals also team played a pivotal role in supporting this work, ensuring seamless integration with the larger network.

Decatur Terminal, which spans 3.6 miles, is the largest flat yard in North America and serves as a vital hub for agricultural products, many of which contribute to the global food supply. Its importance makes it a strategic priority for NS, and the timely completion of this work was essential for minimizing disruptions.

The operation was a highly coordinated effort, with multiple NS teams working around the clock to ensure the project’s success. Key team members included Bryce Diffenderfer, Assistant Superintendent, Midwest Division; Keith Shelton, Track Supervisor; and James Roark, Engineer of Track. All played a critical role in ensuring the work was completed on schedule and with minimal impact on operations. Teams worked in carefully planned shifts to maintain momentum throughout the outage.

While Decatur Terminal was offline, a second team mobilized to replace a 124-year-old plate girder bridge near Lafayette, Indiana. This bridge replacement is part of ongoing efforts to modernize and strengthen NS’ infrastructure. During the outage, the Network Operations Center (NOC) took proactive measures to re-route trains, employing innovative methods to keep traffic moving and minimize delays.

At the Lafayette site, a 220-ton crane was used to remove the old track panel and span, which were then trucked out. The team made strategic modifications to the backwalls before setting new precast concrete sections at each abutment. The crane then carefully lifted and rotated the new bridge structure 90 degrees before lowering it onto the new bridge seat. After the structure was in place, the bridge was flooded with ballast, and a 60-foot-long track panel was flown in to complete the replacement.

Bridge Supervisor Jeremy Dubson and Engineer of Bridges & Structures Michael Waldon played a key role in the meticulous planning and preparation that ensured the success of this complex operation. Their expertise and leadership were instrumental in completing the work safely and efficiently.

A key factor in the success of both project outages was the strategic alignment of their timing, carefully coordinated to capitalize on the optimal time of week for volume and to seamlessly integrate with the bridge outage. This thoughtful scheduling ensured minimal disruption and maximum efficiency.

Matthew Newman, NOC Coordinator, from the Network Operations Center (NOC), along with the dedicated team from the Midwest Division, played a pivotal role in the precise coordination and flawless execution of these critical efforts. During the outage, the NOC took proactive measures to re-route trains with support from road foreman of engines Mike Bruce, Mike Short, and Nolan Wilson to employ innovative methods to keep traffic moving and minimize delays.

These two major infrastructure projects are part of NS’ broader commitment to enhancing its rail network and delivering safe, reliable service to customers across its 22-state network. Similar replacement projects are underway nationwide, as NS continues to invest in the modernization of its infrastructure to meet the demands of the future.