Upgrading and Converting Dozens of Aging Movable Bridges to Remote Operation With Minimal Disruption to Rail Service

• modernising 25 movable bridges to support remote, centralised operation across the CSX network
• Improving safety and reliability for rail crossings over navigable waterways
• Completing work with minimal disruption, with many outages limited to 4-6-hour windows
• Extending the life of legacy bridges while modernising them to meet current regulatory standards 

HDR is helping CSX upgrade 25 movable bridges to improve safety, reliability and operational consistency across its rail network. Many of these structures date back more than a century and were designed for manual operation. The bridges selected for the program serve locations where reliable operation is especially important because they carry rail traffic across navigable waterways and must meet U.S. Coast Guard requirements for marine traffic.

Working with CSX and contractor partner PCL Construction in a construction manager/general contractor (CM/GC) approach, HDR has supported the program since 2015, helping convert movable bridges to remote, centralised operation while extending their service lives. Approximately 20 of the program's 25 bridges have been upgraded, with the remaining structures advancing as funding becomes available and work continues across the system.  

Coordinating Design Across a Complex Program

We serve as design consultant on the program, leading structural, mechanical and electrical engineering and coordinating closely with CSX and PCL through each phase of work. The team evaluates existing bridge conditions, develops upgrade strategies and reviews detailed construction submittals to support implementation in the field.

Each bridge is unique and requires a tailored approach. Decades of repairs and ad-hoc modifications have left many structures with configurations that must be addressed individually before upgrades can begin. HDR’s role is to bring systems back to a reliable baseline, then design improvements that support remote operation while remaining practical to construct and maintain.

The historic Chef Menteur Bridge in New Orleans illustrates the range of challenges involved. Before modernisation, the swing bridge experienced recurring operational issues, including difficulties with span locks and lift rails that affected opening and closing reliability. Located in a hurricane-prone area, it also faced flooding concerns that could affect bridge operations. HDR's upgrades included relocating the operating platform to a higher elevation and modernising key systems, improving operational reliability for both rail and marine traffic while supporting long-term serviceability.

Our approach to the program is grounded in simplicity. While each bridge requires a tailored solution, HDR looks for opportunities to apply proven details and designs across multiple structures. For example, platform layouts and support details that have been successful on previous projects are often adapted for use elsewhere rather than redesigned from scratch. This approach reduces unnecessary complexity, builds on progress already made and helps deliver reliable, maintainable solutions across a diverse network of bridges.

Upgrading Active Infrastructure With Minimal Operational Interruption

Movable bridges play a critical role in both rail and marine traffic. Taking a bridge out of service, even for just a few days, is rarely an option, as even short disruptions can affect rail operations across a wide geographic area.

To keep trains moving, the project team phases construction carefully around live operations. Much of the work is completed alongside existing infrastructure, allowing crews to stage upgrades in advance of track outages. When a track outage is required, the team works within tightly controlled windows to complete critical activities and return the bridge to service.

In many cases, those outages last just four to six hours. Within that timeframe, crews modify or replace key components, install new systems and return the track to service. The ability to plan and execute that work safely and efficiently supports uninterrupted rail service while advancing complex upgrades.

Converting Bridges to Remote Operation

The program goes beyond asset modernisation, shifting CSX’s bridge operations to remote, centralised control. Rather than relying exclusively on personnel at individual bridge locations, operators can oversee bridge movements from a centralised CSX operations center in Jacksonville, Florida, providing greater visibility across the network and a more consistent operating environment.

The upgrades also address long-standing reliability challenges while improving the bridges' ability to support both rail traffic and marine navigation on busy waterways. Many existing bridges experienced frequent mechanical problems, often the result of aging systems and incremental, sometimes improvised repairs made over decades of service. By replacing and modernising key components, the program reduces those failures and improves system performance.

The result is a more reliable network with improved operational consistency. Operators have better visibility into bridge conditions, maintenance needs are clearer and the system performs more consistently across different locations. The benefits extend beyond the railroad itself. By improving the reliability of movable bridges over navigable waterways, the program supports more predictable movement for marine traffic and the industries that depend on waterborne freight. At the same time, the underlying infrastructure is preserved and extended, allowing CSX to continue using these assets well beyond their original design life.