With progress comes change and with change comes challenges.
The Pennsylvania Turnpike Commission (PTC)’s expansion of the Mon-Fayette Expressway meant significant changes for a railroad freight car repair shop operated by the Union Railroad Company (URR) below the Duquesne Boulevard Bridge in Duquesne, Pennsylvania.
Before construction on the Mon-Fayette Expressway project could begin, the PTC needed URR, a wholly-owned subsidiary of Transtar, LLC (Transtar), to reconfigure its Classification Yard, which was last reconfigured in the 1950s.
As part of the Mon-Fayette Expressway PA Route 51 to I-376 project, the PTC plans to replace and realign the existing four-lane steel deck girder bridge that carries Duquesne Boulevard (PA SR 0837) over URR‘s Class Yard and other railroad facilities. The existing bridge will be replaced with a new curved girder structure that will improve the safety and geometry of Duquesne Boulevard. This realignment caused the new bridge location to be directly over the existing car shop building, so the PTC approached URR about moving the building. In addition, a portion of the URR property will be needed to facilitate construction of an on-ramp for the new expressway.
Reconfiguring the Classification Yard: Challenges and Solutions
Transtar owns and operates six Class III freight railroads and a contract switching company transporting raw materials, semi-finished products, and finished products for industries throughout the United States. Its URR subsidiary, a Class III carrier, offers round-the-clock switching services to southwestern Pennsylvania’s Monongahela River Valley and operates 128 miles of track in a 10-mile radius east of Pittsburgh. URR provides rail transportation, car storage, locomotive and car repair, and a variety of transload facilities.
In 2021, URR contracted CEC to help design and obtain permits for upgraded facilities due to the expressway construction. This project included construction of a new railcar repair shop building, which required additional work to realign multiple railroad tracks, improve access roads, upgrade utility infrastructure, and implement best practices for stormwater management (BMPs). In addition to the new car shop, some new rail lines were added for access to the building, as several tracks had to go out of service during construction.
Collaborating for Success: CEC’s Role in URR’s Facility Upgrade
The facility was constructed through a public/private partnership with the PTC as part of its construction of the Mon-Fayette Expressway.
“The Turnpike Commission reached an agreement with URR to acquire certain areas of URR’s land and the old car shop building, all in lieu of ‘eminent domain’, compensating URR in part by reimbursing URR for the cost to construct a new car repair shop building,” says Robert D. Oates, P.E., a principal in the Civil Engineering practice of CEC’s Pittsburgh office. “We helped replace the original car repair shop building with a better building.”
Oates said all permitting and design work had to be approved by both the PTC and URR prior to submitting applications to the reviewing agencies. “We coordinated with the PTC, as well as their contractors and subcontractors. The coordination during the project was heavier than typical projects.”
CEC worked with URR’s project manager, Greg Bykowski, P.E., for two years. “We were working hand-in-hand with the PTC and CEC,” Bykowski said. “As an engineer for a shortline railroad, you look forward to being involved with a project like this due to the challenges associated with constructing a new building. CEC executed myriad tasks to help us deliver a successful project.”
Environmental and Infrastructure Upgrades for the New Railcar Repair Shop
Megan M. Ponzo, P.E., a project manager in the Environmental Engineering and Sciences practice of CEC’s Pittsburgh office, noted that CEC supported all the environmental requirements within this project.
“CEC coordinated the removal and disposal of non-hazardous wastes/materials (solid waste piles, railroad ties, drums, liquids within railcars and tanks) stockpiled on the west side of the site,” notes Ponzo. “CEC also assisted with the planning and permitting of the demolition of the buildings on site and assessed the buildings and existing material stockpiles to determine what options were available to URR for their removal and disposal.”
This environmental expertise showcased in the project has expanded CEC’s services to other Transtar-owned shortlines across the country.
“CEC has been supporting us in our day-to-day environmental needs on our new and on-going projects at our other facilities throughout the country, which has grown our reliance on CEC,” Bykowski said.
Representatives from CEC were in attendance in March 2024 for the official opening of the new rail car repair shop.
The URR facility operates as a comprehensive freight car repair shop with the capacity to store 250 railcars and direct connections to CSX Transportation, Norfolk Southern, Canadian National, and various regional carriers. The new repair shop allows URR to continue to deliver top-tier freight rail car repairs, significantly bolstering safety, reliability, and efficiency for regional freight transportation.
“This new shop is essential for the safety of the railroad system and is equipped to conduct extensive on-site repairs and offer mobile repair services. The facility continues to meet the diverse demands of the regional rail industry,” Bykowski said.
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