CSX Doubles Capacity at Ohio’s Willard Yard with Major Infrastructure Overhaul

WILLARD, OH – CSX has successfully completed a multi-year series of strategic infrastructure upgrades at its Willard Yard in Ohio, effectively doubling the terminal’s daily car handling capacity. The project revitalizes previously underutilized sections of the yard, cementing its role as a critical hub for enhancing fluidity and reliability across the Class I railroad’s extensive network.

Main Body:

CSX announced the completion of a significant, two-year investment program aimed at optimizing its Willard, Ohio, classification yard. The upgrades focused on bringing dormant areas of the facility back into service to improve the overall flow of freight. This initiative directly addresses the operational changes that followed the yard’s conversion from a traditional hump yard to a flat switching facility several years ago, a move that had left certain sections of the terminal underutilized.

The technical scope of the project was extensive and targeted at enhancing ground-level operations. Engineering crews installed new track panels and multiple switches to fully reconnect the former hump area with the main classification yard, unlocking previously inaccessible capacity. In a key operational change, older power switches were converted to more robust hand-throw mechanisms, giving ground crews greater direct control and precision during switching maneuvers. Furthermore, the project involved the complete rebuilding and surfacing of tracks that had been idle since humping operations ceased, supported by an extensive tie replacement program to strengthen the yard’s foundational integrity.

The modernization of Willard Yard is the latest phase in its evolution. The initial conversion from a hump yard—where cars are pushed over a small hill and sorted by gravity—to a flat switching yard was part of a broader network strategy to streamline operations. While that conversion met its initial goals, it created an opportunity for further optimization. This recently completed project represents a follow-on investment designed to maximize the terminal’s entire footprint under the flat switching model, ensuring that every section of the yard contributes to network efficiency and service reliability.

Key Takeaways

• Capacity Doubled: The primary achievement of the project is the doubling of the yard’s daily car handling capacity, allowing for greater volume and fluidity.
• Asset Optimization: CSX has successfully reactivated dormant infrastructure, maximizing the return on its existing real estate and assets in Willard.
• Enhanced Control & Reliability: Upgrades like hand-throw switches and rebuilt track improve safety and give crews better control, contributing to more predictable service.

Editor’s Analysis

CSX’s strategic reinvestment in Willard Yard is a clear indicator of a maturing operational philosophy within the North American rail industry. Following the widespread adoption of Precision Scheduled Railroading (PSR), which often led to the conversion or closure of hump yards, the focus is now shifting to surgically enhancing the resulting flat-switched terminals. This project is not about massive expansion but about intelligent optimization—unlocking latent capacity within an existing footprint. By improving key hubs like Willard, CSX strengthens the resilience of its entire network, making it more competitive against trucking and better able to handle future volume growth without requiring new, large-scale capital projects.

Frequently Asked Questions

What was the main goal of the CSX Willard Yard project?

The primary objective was to double the daily car handling capacity and improve network reliability by upgrading and reactivating underutilized portions of the yard.

Why were parts of the Willard Yard dormant?

Following the terminal’s conversion from a hump yard to a flat switching facility several years ago, certain areas, including the former hump, were no longer integrated into the yard’s daily operations and became idle.

What specific infrastructure work was completed?

The work included reconnecting the former hump area with new track and switches, converting power switches to hand-throw mechanisms for better crew control, and completely rebuilding and surfacing idle tracks with extensive tie replacement.