BNSF Alliance Intermodal Facility Expansion

As one of the busiest intermodal hubs in the United States, the BNSF Alliance Intermodal Facility required a major expansion to accommodate the increasing demand for freight movement. The facility needed to support a projected 1.4 million lifts per year while optimizing efficiency, safety, and operational flow. The challenge was to reconfigure and retrofit existing infrastructure while ensuring uninterrupted operations in a high-traffic environment. Additionally, the project required extensive track modifications, lead extensions, and yard reconfigurations to support future growth and evolving industry demands.

Our firm led the design and construction management for the multi-phase expansion of the Alliance Intermodal Facility. The project focused on enhancing efficiency, increasing capacity, and improving overall functionality.

• Intermodal Facility Enhancements: The expansion introduced a new three-track rubber tire gantry crane module to improve container handling efficiency. Parking expansions were implemented to support growing volume and streamline operations.
• Automated Gate System: A state-of-the-art inbound and outbound Automated Gate System was installed, expediting processing times and reducing congestion.
• Fueling and Administrative Upgrades: The project included the construction of new fueling facilities and a modern employee and administration building to support workforce needs and improve site operations.
• Rail Infrastructure Improvements: The project’s key components included a six-mile mainline relocation, lead extensions, and the reconfiguration of the existing North Yard, which ensured seamless rail movement and increased capacity.

By strategically phasing the expansion, our team ensured that BNSF’s operations continued without disruption while meeting long-term growth objectives.