Engineering excellence drives East Edge launch

By Brett Willi, Senior Communications Manager

Precision upgrades enable double-stack clearance and faster speeds across new high-capacity service.

Norfolk Southern’s launch of East Edge double-stack intermodal service marks a transformative leap in network modernization, and a showcase of Engineering leadership.

Spanning from Chicago to Ayer, Mass., East Edge replaces a slower single-stack route with a faster, high-capacity service. To make it possible, NS Engineering spearheaded extensive infrastructure upgrades in Massachusetts and New York. NS succeeded through close coordination with multiple partners including CSX, short lines Berkshire & Eastern Railroad and Providence & Worcester Railroad, state transportation agencies and local partners.

Why this matters: East Edge demonstrates NS Engineering’s technical expertise and seamless collaboration across teams. It’s a clear step forward in delivering faster, safer freight movement and building the foundation for long-term network growth.

Trackside transformation

Engineering restored and modernized the Voorheesville Running Track (VR Line) between Delanson and Voorheesville, N.Y., a line that had seen limited rail activity for decades. The work was funded by NS and supported by a matching grant from the State of New York.

Key work led by Maintenance of Way & Structures (MW&S):

• Rail and ties: 15 miles of dual rail replaced; more than 13,600 crossties installed
• Support: Two NS capital production gangs, equipped with specialized expertise and machinery for rail and cross tie replacement, played a critical role. The production gangs that maintain NS’ network are highly skilled railroaders, capable of tackling a wide range of infrastructure challenges.

Additional improvements:

• 15 miles of brush cutting and ditching
• 14 crossings renewed or replaced
• Seven greaser pads installed
• Two walking pads built for crew changes

Structural and clearance upgrades

To enable double-stack service, the Design & Construction (D&C) and Bridges and Structures teams raised bridges, reengineered tunnels and enhanced infrastructure:

• Bridges: Beaman Street, Hartwell Street and Squareshire Road in Massachusetts raised 12-18 inches
• Tunnels: Two box culvert tunnels and the open track between them were specially modified in Worcester, Mass., allowing safe clearance through the 2,000-foot section  
• Other work: 150 bridge ties replaced; 27 culverts replaced and inspected
• Crew-change support: A new facility being constructed in Voorheesville, N.Y., will streamline transitions as NS trains move onto and exit CSX’s double main line, reducing dwell time and improving schedule reliability.  

In Worcester, Mass., crews milled the concrete base and directly fastened tie plates to the new floor and rail, creating double stack-ready tunnels.

Signal and safety enhancements

The Communications & Signals (C&S) team delivered several critical upgrades to keep trains moving safely and reliably across the route:

• Nine crossings enabled with renewed operations
• One new crossing installed with CSX in Voorheesville, N.Y.
• Automatic Equipment Identification (AEI) reader installed to track railcars and locomotives via radio frequency tags
• New approach signal added in Delanson, N.Y.

What we’re saying:

“East Edge is another example of how our Norfolk Southern Engineering team leads the way to overcome every challenge and safely deliver complex infrastructure projects with precision, speed, and collaboration.” — Ed Boyle, NS VP Engineering

“Upgrading this route to support high-capacity intermodal service reflects the kind of hands-on, technical work our skilled railroaders do every day. It also demonstrates how we work together as one team to safely and efficiently maintain our infrastructure to meet the needs of our customers.” — Brent Emerson, NS Chief Engineer Line Maintenance

“This project pushed us to think outside the box. From raising bridges with considerable regulatory oversight to reengineering tunnels, our teams adapted quickly and worked seamlessly across departments and with external partners to deliver solutions to meet the challenge.” — Jeff Page, NS System Engineer Design

Upgraded VR Line: New AEI reader, crossings, approach signals, rail, ballast, crossties and culverts deliver a modernized route ready for high-capacity service. First image is a before; others show the in-progress / finished improvements.

Top Image: NS’ Conrail and Delaware & Hudson heritage locomotives lead the first NS double‑stack train to traverse the new East Edge intermodal corridor on Tuesday, Jan. 13. This image shows the train traveling between Worcester and Ayer, Mass., one of the key segments updated by NS Engineering.

Brett Willi leads internal communications for Norfolk Southern, focusing on safety, compliance, operational excellence and employee engagement. He also oversees communications for Engineering and Mechanical. Brett joined NS in 2025, with 20 years of strategic communications, digital content and analytics expertise.