UP receives delivery of “game changing” long rail

Written by Mischa Wanek-Libman, editor
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Shuttle cars carrying long rail arrive at the Stockton weld plant.
Union Pacific

Union Pacific began receiving 480-foot-long rail sections from Japan, which culminates a project more than a decade in the making and according to the railroad, sets a new standard for rail reliability.

 

The railroad says it is the first in the rail industry to import long rail from Japan to its custom facility at the Port of Stockton, Calif. The long rail, made of high-strength, head-hardened continuous-cast rail, requires two welds to create quarter-mile lengths and was developed by UP, Nippon Steel of Japan and Sumitomo Metal Corp.

Union Pacific says it evaluated many options for the 480-foot rail sections, including U.S. manufacturers. The company says it selected the only supplier who met all the necessary requirements for length, strength and weight, which the railroad says are essential in providing safe, reliable rail.

“We’re continuously looking for opportunities to make track maintenance more efficient and effective, as well as increase safety,” said Aaron Hernandez, senior manager-track welding, Engineering. “That includes working with rail manufacturers to improve rail quality. Long rail is a game changer.”

UP notes that implementation required innovation in every aspect of the process. Sumitomo designed “Pacific Spike,” the first ship in the world serving as a long rail shuttle for Union Pacific. It’s outfitted with three cranes synchronized to simultaneously unload five rails weighing 10 tons. The rail is stacked three bundles high onto specially designed shuttle cars to be moved from the dock to storage.

Construction on the Port of Stockton’s roughly 25 acres just finished. Typically, new facilities are built around old rail yards, but this one was designed nearly from scratch. The port has three tracks and two bridges, plus custom storage and welding facilities designed to accommodate the additional rail length.

The $18 million welding facility, equipped with a special overhead crane to lift the rail, began operations at the end of March. UP says that despite the unique nature of the process, standard weld techniques are used to create quarter-mile lengths, which are loaded onto a standard rail train and shipped out for use. UP’s Engineering Department is still determining where the first long rails will be placed.

Pacific Spike has made two deliveries, with a third set for May. At that time, a dedication ceremony will be held.

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