Navigating Diverse Challenges to Expand a Critical Rail Corridor for Continued Port Growth

Abstract: Many seaports that are dependent on rail transportation are dealing with constraints in the capacity of the rail network. Rail capacity has become a critical constraint on future growth at the Port of Longview. The Port is a deep-draft, full-service port operating in Washington on the Columbia River approximately 66 miles upstream from the Pacific Ocean. The Port’s eight marine terminals handle a variety of cargo, including dry bulk materials, break-bulk commodities, and general and specialty cargos. Class 1 rail service by both BNSF and UPRR to the Port is currently provided primarily via the Port’s Industrial Rail Corridor (IRC).  

The original IRC, completed in 2004, connected the Port of Longview directly to mainline rail service. As intended, the new rail link spurred exponential growth -- attracting the nation’s newest grain export terminal and increasing cargo tonnage across the docks by more than 500%. Nearly 20 years after its initial construction, a major expansion is necessary to keep up with customer and market demands.
The multi-year expansion project builds a new six-track rail bed adjacent to the existing corridor, adds two 8,500’ rail tracks and increases the length of the current tracks from 7,500’ to 8,500’ to accommodate full-length unit trains. As capacity needs increase, additional tracks will be added to the already prepared rail bed. Additionally, construction will include new stormwater conveyance and treatment facilities, track operation systems, lighting, utility improvements, and rail crew support facilities.
Completion of the IRC Expansion project will double freight capacity through the corridor, capitalize on the Port’s growth opportunities and generate significant economic benefits for the local community.
Like most established ports, the Port of Longview is set within a landscape of active industrial facilities, high capacity utility infrastructure, private and public properties, and environmentally sensitive areas. The key challenge of the IRC Expansion has been the creation of a rail corridor through this complex landscape with sufficient width to triple the number of tracks serving the Port.
We are currently finalizing the design of this project and anticipate starting construction in early summer 2024. The project team has navigated a broad range of technical and regulatory complexities and challenges including:

design of underwater fills over highly compressible, liquefiable soils
construction of track embankment through open water
impacts of in-water fill on flood plain levels
numerous property acquisitions
environmental impacts
third party utility relocations
construction of track through a closed municipal landfill
satisfying the operating requirements of both BNSF and UPRR

Overcoming these challenges has required extensive communication and negotiation with project partners, municipal governments, adjacent property owners, and third parties to build understanding of the technical challenges, prove that the project was proposing the best possible solutions, and earn the support of a broad group of stakeholders. We would like to share the lessons learned through the planning and design of the project. Particularly the importance of persistence, technical creativity, and a collaborative and transparent mindset in making it possible to dramatically increase the capacity of the rail corridor serving the Port.

How does this project / topic contribute to the advancement of the industry and profession?: Many seaports that are dependent on rail transportation are dealing with constraints in the capacity of the rail network. This project substantially increases the capacity for arrival and departure of trains at a major west coast port. Discussion of this topic will provide examples of solutions, compromises, and strategies that were applied to overcome constraints that are commonly encountered when a new or expanded transportation corridor is needed.

Does the project / topic implement new and innovative techniques, materials, technologies, and delivery methods?: Project includes placement of more than 190,000 cubic yards of underwater embankment, 15-25 feet thick, placed on highly compressible, liquefiable, alluvial soils. Project design has included a test fill placement and monitoring program to forecast long term in-water fill consolidation and subsidence, and these forecasts have been incorporated into the design for utility and track infrastructure on the embankment. The embankment incorporates stabilization materials at its base, engineered fill layers, and a multi-stage construction sequencing plan to reduce the potential for fill material “loss” through soft underwater alluvium and mitigate stability risks associated with the weak and liquefiable in-site soils.

What was the most challenging aspect of your project / topic and how did you handle it to ensure success?: The project team has navigated a broad range of technical complexities including challenging geotechnical conditions, impacts of in-water fill on flood plain levels, numerous property acquisitions, environmental impacts, third party utility relocations, construction of track through a closed municipal landfill, maintaining port operations, and satisfying the operating requirements of both BNSF and UPRR. Overcoming each of these challenges has required extensive communication and negotiation with project partners and third parties to build understanding of the technical challenges, prove that the project was proposing the best possible solutions, and earn the support of a broad group of stakeholders.

Who is the target audience for this paper?: Railway engineers and planners, seaport engineers and planners, seaport policy- and decision-makers will benefit from an understanding of our project goals and the obstacles overcome by the Port to increase critical rail capacity needed for continued growth. Anyone facing the challenge of expanding constrained landside transportation links for a port will find some common experience in the challenges that this project has navigated.