2008 Welded Rail

Welded Rail (in red) on WSOR System

In July 2008, the Wisconsin Department of Transportation awarded WSOR two grants to be used towards capital improvements to the publicly-owned railroad system. One grant, in the amount of $2.8 million is being used to conduct a “phase one” tie replacement program on WSOR’s Madison Subdivision between Milton and Madison, Wisconsin. This project includes replacement of 30,000 ties and installation of 42,000 tons of hard granite rock ballast. Funding for this project came from the following sources: WisDOT $2.8 Million (80%), and WSOR and the Wisconsin River Rail Transit Commission $560,000 (20%). Following this project will be “phase two” rail replacement where WSOR proposes to replace 90 lb jointed rail that approaches 90 years of age with new 115 lb continuous welded rail. Phase two rail replacement could begin as early as July 2009 but is contingent upon availability of state funding.
COST QUICK FACTS

Rail: $2,836,660.50
Tie plates: $943,400
Spikes: $102,000
Switches: $160,000
Freight to WSOR: $28,000

New Track speed: 40mph
A second grant, in the amount of $4.8 million is being used to install 115 lb continuous welded rail between Hartford and Horicon, Wisconsin, a distance of 14 miles. A first rail train containing seven miles of rail was delivered in early July 2008 with the second rail train delivered in early September 2008. Both rail trains delivered quarter mile sections of 115 lb rail that was unloaded on site. Field welding and installation began mid summer and completed in October. Surfacing and quality control will be completed during the fall. Once finished, these projects will enhance public safety in Wisconsin communities and will provide for a stronger and more competitive rail system for Wisconsin businesses.This segment of track is expected to carry 5.1 million gross tons annually by the year 2013, a 43% increase from today. Carloads are expected to increase by 40% in the same time period.

Photos below show the welded rail installation on the Milwaukee Sub between Horicon and Hartford. A 30-man rail gang installs anywhere from 4800 to 6500 feet of rail per day, depending on crossings and bridges. WSOR crews are using a backhoe and a track crane to pull the rail off the “threader” car. The rail is attached to the anchor vehicles using cables and bolts and held in place while the locomotive proceeds slowly ahead allowing the rail to be pulled out of the cars and laid on the ground next to the existing railroad infrastructure.

Brand new welded rail with 2008 dating.

Threader car as welded rail is pulled off rail train.

New rail is cut at road crossing during laying.

Track crane anchors rail while train pulls ahead.

BEFORE: Old 90 lb jointed rail.

AFTER: New 115 lb welded rail.