Summary

Burlington Northern Santa Fe operates one of the largest rail networks in North America, with 33,000 route miles (53,000 route kilometers) covering 28 states and two Canadian provinces. As a result, BNSF’s 2002 maintenance program is expected to approach $800M (USD). To insure that resources of this magnitude are utilized appropriately, BNSF performs a comprehensive analysis of its infrastructure aimed at reducing cost, improving reliability, and extending asset life.
Tools employed to achieve these goals include World Class Maintenance, preventive and predictive technologies, Six Sigma techniques, and Lean Processes. Because rail is the company’s highest-value asset, the goal is to extend its life as long as possible without jeopardizing safety and operational reliability. This is accomplished through attention to initial product quality, preventive rail grinding, and efficient rail lubrication. To supplement its conventional wood tie population, BNSF has tested and will continue to test a number of engineered ties including steel, plastic, concrete, and composite wood. However, creosote-treated, hardwood ties remain the backbone of the tie maintenance program. Good drainage and clean ballast conditions are major components in maximizing tie life. To attain these qualities, BNSF accomplishes a significant level of both track undercutting and shoulder ballast cleaning in conjunction with an aggressive track surfacing program. Emphasis in signal technology is placed on automation that eliminates train delay and reduces switching labor. In addition, the installation of wheel impact load, truck performance, hot bearing, and dragging equipment detectors enhances operational safety and reduces maintenance costs. One current challenge with track maintenance is being able to accurately predict when and where it will be needed based on the current state of the track. The use of Track Predictive Indices will largely overcome that challenge. BNSF is convinced that a track maintenance program founded on World Class Maintenance will support a scheduled railroad, reduce reactive maintenance activities, and maximize efficiencies.