DONE GETTING IT

Projects Are Tough, But Rewards Can Be Great

By David C. Lester, Editor-in-Chief

Most companies spend a lot of time on projects of various kinds. Infrastructure projects, though, can be particularly challenging because most take place outside; they o en change the appearance of the built environment and are usually dangerous. Proper planning and management, though, can mitigate the safety risks. Moreover, when the project is complete, the planners and those who built the infrastructure enjoy a unique level of satisfaction.

While there are hundreds of projects to read about and feature, we’ve chosen two for this issue that we thought were especially interesting. We begin with a story from Progress Rail, which completed a set of switches that, as the company says, “looks like a puzzle.” Second, who is building railroad stations these days? Well, Brightline, for one. We’ll look at the company’s recent completion of the Aventura and Boca Raton stations and Brightline’s showcase station at the Orlando International Airport, which will be the temporary termination point for the line extension north from West Palm Beach. e Orlando line will open later this year, and passengers can enjoy higherspeed rail travel from Orlando to Miami and several points between the two.

Progress Rail’s Puzzle

When a railroad puzzle switch at the Port of Beaumont in Texas was identi ed as aged and unreliable, impeding car operations, and a cargo safety hazard, Progress Rail was contracted by Trans-Global Solutions Inc. (TGS) to supply a switch with optimized eciency and reliability.

e Caterpillar company redesigned a new, custom puzzle switch – consisting of a double crossover containing two #6 turnouts and two double slips with a crossing diamond in the center.

Progress Rail’s trackwork team in Decoursey, Ky., manufactured and assembled the complex in an enclosed transit assembly building. A er all components were assembled, they t within a 165-foot by 39-foot space. e puzzle switch was labeled and color-coded at the end of each section to ensure accurate and e cient reassembling of panels on site a er their 1,000-mile journey by truck from Kentucky to Texas.

“ e tight spatial constraints, along with its complex design, made this an ideal project for the Progress Rail Trackwork team,” said Patrick Jansen, Senior Vice President for Progress Rail. “From a site visit to con rm the geometry through the completion and submission of the detailed drawings, our Engineering team ensured our work would meet the highest quality standards. All components were manufactured and assembled at our Decoursey Trackwork facility before nal inspection and shipment to the Port. We are proud of our team’s successful execution of this complex project to meet our customer’s requirements and provide their operation with increased e ciency and reliability.”

Upon arrival at the Port of Beaumont in December 2021, TGS staged and stocked the disassembled puzzle switch at an unoccupied, secure property and parking lot. is put the switch components near the installation area and provided security before installation. In March 2022, TGS began managing the installation, including two new switches at the leads to the puzzle switch and civil preparations.

August 2022 marked the completion of the engineering, fabrication, and installation of the replacement puzzle switch, which today expands the Port of Beaumont’s ability to set four routes, increases the volume of car movement in a compact space and ensures maximum cargo handling for the Port by rail.

“ e Port of Beaumont is incredibly proud of this project,” commented Brandon Bergeron, P.E., Director of Engineering for the Port of Beaumont. “Although it was on the ‘small’ side in terms of nances, it is huge in terms of the e ciency and function of the Port.”

Operationally, the new switch design improves the e ciency and operability of cargo movements, ensures reliable cargo movement of two unit trains can continue and saves the Port annual switch maintenance costs. From a safety standpoint, the puzzle replaces a deteriorating switch with lower structural integrity and bearing loads than recommended, decreases the possibility for common derailments, and increases the safety for rail cargo handlers, who can handle two unit trains simultaneously.

“We studied various options for modernizing the switches in that area, but a completely rebuilt puzzle switch was the only option that allowed us to function within the tight spatial constraints and demands of Port business,” Mr. Bergeron added. “We would gladly score our satisfaction with the project with the highest marks.”

Launched in October 2020, the project was completed within budget, without any recordable injuries, and ahead of schedule in the Fall of 2022, meeting the fabrication and installation objectives the Port and its engineering design team set forth.

Organizations involved in the project include Trans-Global Solutions Inc., Progress Rail, a Caterpillar Company, Port of Beaumont Board of Commissioners, Lanier & Associates Engineering, Railroad Infrastructure and Terminal Development, Kansas City Southern, Burlington Northern Santa Fe, Union Paci c, Southeast Texas Regional Planning Committee and Louis Dreyfus Company.

New Brightline Stations

It’s not too o en that you hear about the opening of new railroad passenger stations. However, Brightline has completed three within the past few months, and two are already open. e station at Orlando will open when the railroad begins service on its Orlando line from West Palm Beach later this year.

Orlando e Orlando station spans three stories, featuring a new design and a synthesis of luxury amenities that meet the demand of today’s traveler. e journey begins at the main entrance, located o the airport’s expansive two-story glass atrium. Once inside the station, passengers can purchase tickets from guest services or one of several self-service kiosks and check luggage before proceeding through the touchless turnstiles into the security screening area. Brightline is currently the only rail system in America that screens all passengers and bags before boarding.

Patrick Goddard, president at Brightline, said, “ is world-class train station continues our mission of transforming train travel in America. We have carefully thought through each detail of this station to ensure that it exceeds the modern traveler’s expectations.” e 37,350 square foot station is in the heart of the Orlando International Airport’s new 80,000 sq. . Terminal C and connects directly to the airport’s parking deck C, which will have more than 350 parking spaces reserved for Brightline passengers. In under ve minutes, an automated people mover connects the terminal to the rest of the airport facilities, including Terminals A and B.

Passengers will access trains by escalator or elevators to the rst level platform and board from one of two new track platforms. ese platforms are 1,000 feet long and will accommodate a train with four coaches and two locomotives that will transport passengers on the Orlando to Miami route in just over three hours.

Aventura e Aventura station opens one hour before the rst train departure and closes ten minutes a er the last train arrival. e initial schedule for trains operating in and out of the station is designed to optimize commuter patterns and will focus on peak morning and evening weekday service. During non-peak hours and weekends, Brightline will provide service approximately every other hour. Regular hourly service will continue in West Palm Beach, Fort Lauderdale, and MiamiCentral.

Brightline’s Aventura station opened for revenue service on December 21, 2022. is station has 34,000 sq. . and was designed to LEED (Leadership in Energy & Environmental Design) Silver criteria as part of Brightline’s e ort to reduce its carbon footprint. e LEED Silver station design features include a solar canopy, installation of electric charging stations, a selection of materials to increase healthy indoor spaces, and smart technology to reduce water use.

Miami-Dade County invested $76 million in the Aventura station and created more than 400 jobs during construction. Now that the station is open, it is expected to generate signi cant economic bene ts. e station will bring $90.8 million annually in economic impact and $2.7 billion over 30 years.

Boca Raton

e Boca Raton station and platform occupy 22,000 sq. . on a 1.8-acre site. e station also opened for revenue service on December 21, 2022. As with the Aventura station, the Boca Raton station will open one hour before the rst train departure and close ten minutes a er the last train arrival. is station will also focus on peak morning and evening weekday services, and during non-peak hours and weekends, Brightline will provide service approximately every other hour. Regular hourly service will continue in West Palm Beach, Fort Lauderdale, and MiamiCentral.

e funding for the Boca Raton station began in 2021 when Brightline was awarded a $16.3 million Consolidated Rail Infrastructure and Safety Improvement (CRISI) Grant from the FRA to fund a portion of the construction of the Brightline train station, parking garage, and associated rail infrastructure. In addition to the CRISI grant, the City committed $9.9 million toward funding the parking garage. e balance of funding, approximately $30 million, was contributed by Brightline.