Norfolk Southern Expands Defect System; Supports $7.7B Customer Spend

Norfolk Southern Railway will proceed with a network-wide expansion of its wheel defect detection technology. The decision follows the successful implementation of the “wheel integrity system” at its Burns Harbor rail yard in Portage, Indiana, which went operational on November 24, 2025. This technological deployment is a component of the infrastructure upgrades necessary to support significant industrial growth along its routes.

The system utilizes six synchronized cameras to capture detailed images of every wheel on trains passing through the detection point. An analysis engine processes these images to automatically identify and flag structural defects that may not be visible during manual inspections. This automated process is designed to improve detection rates and increase operational velocity by reducing manual inspection times.

A key performance indicator from the Burns Harbor pilot was the system’s identification of a casting flaw on a vendor-supplied wheel set. Norfolk Southern’s follow-up investigation into the anomaly confirmed seven separate defects across multiple components from the same batch. This finding was substantial enough to trigger an industry-wide recall of the compromised wheel sets, preventing potential failures on the mainline.

The investment in such safety and reliability systems runs parallel to major industrial investment from Norfolk Southern’s customers. According to company reports from early 2026, customers advanced over 60 industrial development projects along its network in 2025. These projects represent a total of $7.7 billion in private investment for new or expanded facilities that require direct rail service.

Maintaining high levels of asset integrity is fundamental to securing this type of long-term commercial growth. The company reports a current pipeline of more than 500 U.S. manufacturing projects in the site selection phase that could add to its rail-served customer base.

Expansion of the wheel integrity system is an operational prerequisite for reliably handling the anticipated freight volume from these new and expanded facilities. Specific timelines and locations for the system’s broader rollout have not yet been publicly disclosed by Norfolk Southern.