Track Design Expertise

Railroads have a wide variety of facilities and situations with different track needs. Crouch Engineering provides expert track design services for all the situations.

Track Design

Track Rehabilitation Design and Project Management

Over the past 23 years, Crouch Engineering has designed and managed more than 160 annual track rehabilitation programs for 10 Tennessee Shortline Railroads Authorities, performing the following tasks:

  • Conducted topographical surveys and track inspections as needed to develop plans and specifications.
  • Developed a detailed scope of work for each project (rail replacement, timber and surfacing projects, turnout repairs and replacement, grade crossing rehabilitation, etc.)
  • Prepared track rehabilitation and construction plans and construction details.
  • Prepared specifications for each individual project component and construction item.
  • Prepared bidding documents, including general conditions, scope of work, specifications, regulatory requirements, information for bidders, bonding and insurance requirements, bid sheets, track charts and location maps, job showing notes, addenda, etc.
  • Conducted the competitive public bid process for each project.  This includes setting up and managing the pre-bid meeting (job showing), bid opening, bid tabulation, preparing all correspondence for the Authorities, and assisting with the Award of Bid and request for state contracts.
  • Provided construction phase services including construction project management, construction observation, review of contractor invoices, processed invoices for payments, tracked project costs and managed change orders.
  • Completed project documentation on digital media, advertised project completion and release of liens, and completed correspondence and notices for contract closeout.

Track and Roadbed Design for Industrial Facilities

Crouch Engineering has prepared site and track plans for more than 200 industrial development track projects for railroads and railroad customers.  Track plans have included greenfield site development and modifications and expansions for existing rail-served facilities. 

Track and Roadbed Design for Sidings and Siding Extensions

Crouch Engineering has prepared plans for many siding and siding extension projects across the U.S. for many railroads.  These plans are developed through meetings with the railroads to determine service requirements, length of trains being operated, operational requirements, grading and structures anticipated, location of grade crossings, best location, etc.

Track Design for New Railroad Yards

Crouch Engineering has provided complete engineering services for the design of new railroad yards and facilities, from planning and survey, to design, permitting, and construction phase project management.  Crouch Engineering has also assisted clients in negotiations for project funding, grants, and property acquisition.

Track Design for Existing Railroad Yard Expansions / Capacity Projects

Crouch Engineering has provided complete engineering services for the design of yard expansions, yard capacity improvement projects, and track modifications, including surveying, design, permitting, and construction phase services.  These projects typically involve adding capacity within the footprint of an existing railroad yard.

Track Design for Double Track – Multiple Track Projects

Crouch Engineering has prepared plans for Class 1 Railroad double track projects and multiple track projects.  Refer to AE-5 Forms herein for descriptions of the NSR Grove, KY Double Track Project and the NSR Front Royal Double Track Project

Track Design for Speed Improvement Projects

Crouch Engineering has prepared plans for many speed improvement projects.  Railroad line capacity and service can be improved by increasing the operating speed over line segments, reducing slowdowns and bottlenecks.  These projects typically involve alignment improvements, and other changes to track layout and geometry.

Track Design for Intermodal Facilities

Crouch Engineering has performed design services for ports, port support facilities, new intermodal facilities, modifications to existing intermodal facilities and yards, and has completed concept studies and plans for proposed inland ports and intermodal facilities.

Track Design for Passenger and Commuter Rail Operations and Improvements

Crouch Engineering has performed planning services, route planning and evaluation, feasibility studies, concept design, surveying and mapping, preliminary engineering design, permitting, plan production, cost estimating, project coordination, project management, and construction phase services for passenger and commuter rail projects.  Project work includes speed improvement projects, station locations, platform design, platform track design, station site plans, servicing facilities and main line track relocations and improvements.

Railroad Route Feasibility Planning and Studies

Crouch Engineering performs route planning and feasibility studies for proposed railroad routes.  Our planning and preliminary engineering services have been provided for potential railroad construction projects across the U.S., and in the countries of Guinea, and Ghana in West Africa. 

Track Design Projects by Crouch Engineering

4.4 Mile Double Track Project and Bridge Upgrades

The new double track project consisted of topographic surveying, track and bridge design, utilities relocations, environmental permitting, the bid phase, construction staking and construction project management for a new 4.4 mile double track mainline. The project included upgrading and widening an existing 400-foot long, 70-foot high single track bridge over Pitman Creek to accommodate double track, and design of a new highway overpass on Doc Newell Road, crossing over the Norfolk Southern Railway double track section.

Briley Parkway Widening, Railroad Realignment, New Bridge Design

The new double track project consisted of topographic surveying, track and bridge design, utilities relocations, environmental permitting, the bid phase, construction staking and construction project management for a new 4.4 mile double track mainline for the Nashville and Eastern Railroad Authority. The project included upgrading and widening an existing 400-foot long, 70-foot high single track bridge over Pitman Creek to accommodate double track, and design of a new highway overpass on Doc Newell Road, crossing over the Norfolk Southern Railway double track section.

Kiamichi Railroad - Widening of US Hwy 70

In reviewing plans for the proposed US 70 widening project, working on behalf of the Kiamichi Railroad, Crouch Engineering offered a cost saving railroad alignment change concept to ODOT and the Railroad, eliminating a $2 million temporary bypass track and preventing rerouting RR traffic onto another rail carrier. The 3,500 foot line change was constructed off-line, with new ties and 136 RE CWR, after the new grade separation was constructed. Crouch Engineering surveyed and designed the alignment change.

US 70 (SR 24) / SR 109 Main Line Alignment Change

Crouch Engineering designed a 3.2 mile realignment of the Nashville and Eastern mainline in conjunction with the US 70 highway widening project and the SR 109 highway widening project, eliminating 2 major grade crossings, on behalf of Nashville and Eastern Railroad Authority (NERA). The project included design of a grade separation at SR 109, two concrete and steel 3-span ballast deck bridges over streams, and a steel through plate girder bridge over US 70.

New Double Track Mainline and Grade Crossing Upgrades

The Norfolk Southern Railway Mainline track runs north to south through Warren County, Virginia. The project is located north of Front Royal, north of Interstate Highway 66, roughly parallel to Highway 340, south of Ashby Station Road. Norfolk Southern Railway Corporation engaged Crouch Engineering, PC to design, permit, bid and provide erosion control monitoring for a five-mile double mainline extension. The project consisted of the construction of a 21,000 foot railroad second main line track, parallel to the existing main line track. The construction of the proposed main line track required approximately 19 acres to be cleared, grubbed and graded to accommodate the proposed sidetrack. Ten culverts were replaced and three culverts were extended. There are four grade crossings that were upgraded. Access to the Virginia Inland Port, and several other industries were redesigned to provide and maintain rail service to the local industries. Crouch also worked with the VA DRPT and VA Outdoors Foundation to reduce and mitigate impacts to four conservation easements along the route.

Mercedes-Benz USBI Railroad Yard Expansion

Crouch Engineering, P.C. designed two new staging tracks (over 10,000 track feet) and the extension of five auto load-out tracks and related appurtenances for Mercedes-Benz in Vance, AL. The USBI project enabled Mercedes-Benz to expand its export business, doubling its loading capacity. Crouch Engineering also designed the yard expansion at Colonel's Island, Anguilla GA, increasing inbound capacity for export cars at the Georgia Ports Authority.

Toyota – Southeast - Railroad Siding/Capacity Expansion

The Project consisted of designing a new 3,500 track foot siding to serve Toyota-Southeast in Commerce, Georgia. Construction required an Aquatic Resources Alteration Permit (ARAP), gabion wall design and environmental permitting.

Anguilla Rail Yard Expansion

Crouch Engineering redesigned the railroad yard at Anguilla, GA in order for the port facility to accommodate additional auto and grain export traffic. The design consisted of: extending four tracks by approximately 1,000 track feet each to allow additional storage for autoracks (car carriers); construction of new ladder tracks on both the north and south ends of the yard, and rehabilitation of the existing yard tracks. The project, originally estimated at $4.5 Million, was designed and built for $1.2 million.

Norfolk Southern Railway / Amtrak Passenger Project

The Crouch Engineering design team worked closely with Norfolk Southern, the Virginia DRPT, Amtrak, CSX, local agencies, utilities, and regulators to plan, survey, design, permit, bid, manage, and stake out the following projects, which were a part of the overall Norfolk to Petersburg, VA Amtrak project:

- New Amtrak Station Platform and Platform Track; Harbor Park, Norfolk, VA Survey, design, utilities, permitting, bid phase, and staking - 2,000 TF platform track, main line realignment, I-95 Crash Walls, a new 800’ passenger station platform, and platform track.

St. Julian Amtrak Servicing Facility and New Wye Tracks - Norfolk, VA – Planning, survey, design, utilities, permitting, bid phase, and staking wye tracks (8,600 TF), main line realignment, & new Amtrak passenger train servicing facilities and wye to be used for Amtrak passenger trains to turn around

- NSR - CSXT Connection Track – Survey, design, permitting, utilities, bid phase, and staking for a 7,000 TF connection track and CSXT double track.

- New Double Mainline and Auto Ramp Bypass, Petersburg, VA – survey, design, permitting, bid phase, and staking for a new 6,200 TF mainline bypass

- Siding Extension & Highway Realignment, Petersburg, VA – survey, design of track, bridge overpass, and highway realignment, utilities, permitting, bid phase, project management., and construction staking for the 0.5 mi Johnson Rd. Realignment and railroad bridge overpass widening.

- Redesign of Portlock Yard, Chesapeake, VA – planning, survey, design, utilities, permitting, bid phase, and staking for additional storage tracks, a new switching lead, and redesign of other yard tracks to allow passenger trains to move through the yard without interference from yard switching operations.

Redesign of the Norfolk Southern Railroad South Yard

Crouch Engineering performed survey, track, grading, and drainage design, permitting, erosion control plans, coordination with the City of Mobile and ADEM, bid phase, and construction staking for the redesign of South Yard, to increase railcar storage capacity. The existing ADM unloading facility and rail access had to be preserved. Existing yard drainage was poor - drainage improvements were designed for the entire yard. The project also involved relocation of an existing C&S microwave communications tower.

Citrus Rail Project – New 10 Mile Railroad Main Line

Crouch Engineering performed track and roadbed design, grade crossing design, culvert design, bid phase, and construction project management and construction phase engineering for a new, greenfield ten-mile long main line, a siding for a new cane elevator loadout, a new storage yard and multiple loading tracks for the citrus plant. The project was completed on time and under budget by 30%, allowing for the replacement of an additional nine miles of 85 AS rail with new 136 RE CWR and OTM.

KWT Railway New Locomotive and Railcar Repair Shop Design

Crouch Engineering performed planning, estimating, surveying, mapping, design, bid phase services, and construction project management services for a new locomotive shop in Paris, Tennessee for the KWT Railway. The shop has capacity for maintaining four locomotives. The project included track design for two shop tracks and a new switching lead track to serve the shop, and design for an overhead crane.

Enterprise South Railroad Railroad Locomotive and Railcar Repair Shop Relocation

Crouch Engineering performed planning, estimating, surveying, mapping, environmental permitting, design, bid phase services and construction project management services for the removal of an existing locomotive and railcar repair shop and redesign and reconstruction of the shop to be rebuilt on a new site in Chattanooga, TN. The project included track design for two shop tracks and a new switching lead track to serve the shop, as well as site design for the shop, parking and access road.

Lhoist North America New Railroad Locomotive and Railcar Repair Shop / Heavy Equipment Shop

Crouch Engineering performed planning, estimating, surveying, mapping, environmental permitting, design, bid phase services and construction project management services for the design of a new locomotive and railcar repair shop / heavy mining equipment shop, on the Lhoist North America Mine site in Crab Orchard, TN. The project included track design for two shop tracks, a locomotive pit and transfer table and a new switching lead track to serve the shop, as well as site design for the shop and parking.

New Railroad Locomotive and Railcar Repair Shop / Warehouse / Offices / and Freight Yard

Crouch Engineering performed planning, estimating, surveying, mapping, environmental permitting, design, bid phase services and construction project management services for the design of a new railroad freight yard, with a railroad locomotive and rail car repair shop / warehouse, offices, wash pad, and SPCC containment system on a greenfield site for South Carolina Central Railroad in Darlington County, SC. The project included track design for two shop tracks, a locomotive pit and transfer table and a new switching lead track to serve the shop, as well as site design for the shop / warehouse, access road, utilities, wash facilities, and parking.

San Luis and Rio Grande Western RR Shop Design

Crouch Engineering performed planning, estimating, surveying, mapping and design services for a new locomotive and railcar repair shop on the San Luis and Rio Grande Western RR in Alamosa, CO. The project included track design for two shop tracks, a locomotive pit and transfer table and a new switching lead track to serve the shop, as well as site design for the shop.

Tennessee Southern Railroad New Locomotive and Railcar Repair Shop

Crouch Engineering performed planning, estimating, surveying, mapping, design, bid phase services, and construction project management services for the design of a new railroad locomotive and railcar repair shop on the Tennessee Southern Railroad site in Mt. Pleasant, TN. The project included track design for two shop tracks, a locomotive pit and drop table, and a new switching lead track to serve the shop, as well as site design for the shop.

Alabama Gulf Coast Railroad Shop Design

Crouch Engineering performed planning, estimating, surveying, mapping and design services for a new railroad locomotive and railcar repair shop on the Alabama Gulf Coast Railroad site in Fountain, AL. The project included track design for two shop tracks, a locomotive pit and transfer table, wash facilities and a new switching lead track to serve the shop, as well as site design for the shop.

Locomotive Shop Design – 611 Steam Locomotive

Crouch Engineering has performed planning, estimating, surveying, mapping and preliminary design services for the design of a new locomotive repair shop for the Fire Up 611 Project, for the N&W 611 Steam Locomotive, for the Virginia Museum of Transportation in Roanoke, VA. The project included redesign of the museum lead track and yard tracks, design for two shop tracks and a locomotive pit, as well as site design for the shop. Full design is expected to start in the 4th quarter, 2014.

Hartford CT New Locomotive and Railcar Repair Shop Design

Crouch Engineering performed planning, estimating, surveying, mapping and design services for the design of a new railroad locomotive and railcar repair shop on the New England Central Railroad site in Hartford, CT. The project included track design for two shop tracks and a locomotive inspection pit, as well as site design for the shop.

Railroad Locomotive and Railcar Shop Modifications

Crouch Engineering performed planning, estimating, surveying, mapping, and design services for the design of a new locomotive inspection pit at the Knoxville Locomotive Works, in Knoxville, TN. The project also included track design for tracks serving the shop.

Volkswagen – Bonny Oaks Dr. Underpasses, Yard Expansion, Hickory Valley Road Overpass Replacement and NSR Connection

Crouch Engineering worked with Hamilton County, Enterprise South, the HCRA and Norfolk Southern Railway (NSR) to provide planning, surveying, permitting, design and related services for the redesign and expansion of an existing railroad yard to serve Volkswagen in Chattanooga, TN. As a part of the Volkswagen Project, working with NSR and Hamilton County, Crouch Engineering designed a new connection with NSR, and facilitated a connection with CSXT. In addition, Crouch Engineering designed the replacement of the Bonny Oaks Drive single track overpass with three new through plate girder bridges, accommodating the tracks necessary for the expanded yard and widening of Bonny Oaks Drive as well. Crouch Engineering also designed the replacement of the Hickory Valley Drive Overpass over the Enterprise South Railroad to accommodate heavier highway traffic as well as provide additional track clearance for the railroad.

13 Mile Long Railroad Bypass and Right-of-Way Swap

Crouch Engineering represented the West Texas & Lubbock Railroad as the liaison with the City of Lubbock and Texas DOT for the plan review and construction phase engineering services for the railroad / highway right-of-way swap and 13 mile long railroad bypass around Lubbock, TX. Crouch Engineering performed plan review and provided more than 300 plan corrections and improvements for the main line and yard plans. Crouch also provided full time construction project management during construction, responsible for QA/QC, project documentation and construction observation. The project provided the City with the right-of-way for a new SW-NE road corridor.

NERA – SR-24 (US 70), and SR 109 Grade Separation Projects

Crouch Engineering worked with the Nashville and Eastern Railroad Authority and TDOT to plan, survey and design a 3.2 mile long railroad main line realignment. This project eliminated two major railroad/highway grade crossings, providing grade separations at SR 109 and SR 24 (US 70) and improving railroad track geometry for higher speed operation in the area. Crouch performed all

- planning

- topographic surveying and mapping

- environmental permitting

- track and roadbed design

- one minor grade crossing redesign

- bridge design for two new ballast deck concrete/steel bridges at stream crossings (two bridge demolitions)

- and a new through plate girder bridge over SR 24 (a 5-lane highway widening project).

Crouch Engineering also worked with TDOT to present the project in Public Meetings.

NERA – Briley Parkway (SR 155) Widening and Railroad Realignment Project

Crouch Engineering worked with the N&ERR and TDOT to plan, survey, and design a 3.2 mile long railroad main line realignment that eliminated 2 major railroad/highway grade crossings, providing grade separations at SR 109 and SR 24 (US 70), and improving railroad track geometry for higher speed operation in Wilson County, TN. Crouch performed all

- planning

- topographic surveying and mapping

- environmental permitting

- track and roadbed design

- one minor grade crossing redesign

- bridge design for two new ballast deck concrete/steel bridges at stream crossings (two bridge demolitions)

- a new through plate girder bridge over SR 24 (a 5-lane highway widening project).

Crouch Engineering also worked with TDOT to present the project in Public Meetings.

Hartsville Yard Relocation

Crouch Engineering worked with RailAmerica; the South Carolina Central Railroad; the City of Hartsville, South Carolina; Darlington County, South Carolina; Coker College; and the Governor’s School of South Carolina to relocate the Railroad’s office and yard from Hartsville to Darlington County, South Carolina. Vacating the Railroad R.O.W. permitted linking the two school campuses.

Crouch assisted with cost negotiations, and was responsible for planning, surveying, environmental permitting, the design of yard tracks, passing tracks, a new office, a new railroad locomotive and railcar repair shop with warehouse and all yard site work. Crouch Engineering assisted in acquiring the new 27 acre yard site for a cost of $10.

When it came time for construction, Crouch Engineering performed the project turnkey, utilizing a local grading contractor, and managed the construction of the project.

TDOT – SR 22

Crouch Engineering performed plan review, retaining wall design, shoring plan review and construction observation for a 177 foot long state highway bridge over the Railroad. Crouch Engineering worked closely with TDOT to develop a roadbed slope stabilization design to prevent slope erosion and settlement, and maintain railroad ditch flow. Plan review began in 2009, construction was completed in 2013.

Lhoist North America Railroad Tunnel Rehabilitation

Crouch Engineering worked with Lhoist North America (formerly Franklin Industrial Minerals) to assess the conditions of the railroad’s 900 foot long tunnel east of Westel, TN, and developed a methodology and plans for tunnel rehabilitation. The western portion of the tunnel was stable; however, the eastern portion had soil overburden, and the tunnel itself was constructed of timber sets. Groundwater infiltration and soil failures had been an ongoing maintenance problem for the railroad. Crouch evaluated several options for remediation and rehabilitation, including opening cutting, a metal arch replacement and the use of pre-cast replacement sections. The final method selected was a concrete liner, utilizing post-grouting. Crouch Engineering developed plans and specifications for the concrete liner project.

South Central Florida Express and FL DOT

Crouch Engineering provided full time construction management services, QA/QC, construction observation, contractor coordination, reporting and documentation for the Citrus Rail Project. The project included construction of a completely new ten-mile long main line, a cane elevator siding, a three track storage yard and multiple car loading tracks for the South Central Florida Express near Clewiston, FL. Crouch Engineering’s project manager was responsible for monitoring the general contractor and subs to ensure that the project was constructed in general conformance to the plans and specifications. These plans and specifications were also prepared by Crouch Engineering.

Grove to Woods Double Track Project / Pitman Creek Bridge / Doc Newell Road Bridge, and County Road 2747 Realignment and Utility Relocations

Crouch Engineering provided full time construction management services, QA/QC, construction observation, contractor coordination, reporting and documentation for the Pitman Creek Bridge upgrades for double track and 286k, the new Doc Newell Road Overpass over the Norfolk Southern Railway (NSR), the County Road 2747 relocation, and a portion of the NSR Grove to Woods, KY Double Track Project.

The project included:

- construction of a 4.5 mile long double track section of the NSR

- upgrading a single track, 400’ long, 70’ high bridge over Pitman Creek to accommodate a second track and 286k loading

- construction of a new road alignment for Doc Newell Road

- a new highway bridge over the NSR

- slope stabilization, and other work

Crouch Engineering’s project manager was responsible for monitoring the general contractor and subs to ensure that the project was constructed in general conformance to the plans and specifications. These plans and specifications were also prepared by Crouch Engineering.

Johnson Road Bridge Overpass Over Norfolk Southern Railway

Crouch Engineering provided full time construction management services, QA/QC, construction observation, contractor coordination, reporting, and documentation for the Johnson Road Highway Bridge and highway alignment change for the widened overpass over the NSR in Petersburg, VA.

The project included construction of a 2,500 foot long highway realignmernt, and construction of a new highway bridge, keeping both the road and railroad in service during construction.

Crouch Engineering’s project manager was responsible for monitoring the general contractor and subs to ensure that the project was constructed in general conformance to the plans and specifications. These plans and specifications were also prepared by Crouch Engineering.