Norfolk Southern Engineering delivers over $1 billion in systemwide upgrades alongside major safety gains

By Brett Willi, Senior Communications Manager

Upgrades strengthen the Norfolk Southern railway network and help ensure safety for employees, customers and communities

In 2025, Norfolk Southern’s Engineering team delivered tremendous safety achievements: Zero fatalities and a 27% reduction in Federal Railroad Administration (FRA)-reportable injuries year-over-year. Alongside these gains, the team advanced critical infrastructure improvements across the company’s 22-state network, reinforcing the safety, speed and resilience of our railroad.

These achievements were made possible by the dedication of teams across Maintenance of Way & Structures, Program Maintenance, Communications & Signals, Bridges and Structures and Design & Construction (D&C) — working together to deliver results that matter.

“Safety is the foundation of everything we do, and our more than 5,000-strong Engineering organization proved that commitment in extraordinary ways in 2025,” said Ed Boyle, NS VP Engineering. “At the same time, we delivered exceptional infrastructure improvements through extensive planning and outstanding execution. These results show what’s possible when the skill, precision and expertise of our industry-leading railroaders come together every day.”

Key projects included:

Safety Infrastructure

• 375 grade crossing protection warning systems installed
• 16 hot box/bearing detectors added
• 10 hot wheel detectors installed
• 157 public improvement projects completed
• 79 roadbed stabilizations finished
• 18 retarders replaced (3 group and 15 skates)
• 3 Digital Train Inspection (DTI) portals constructed and in service
• 1.56 million track miles testing with Automated Track Geometry Measurement System (ATGMS) locomotives
• 41,000 miles of track tested with two geometry cars

Track, Bridges and Structures

• 517 track miles of rail replaced
• 2 million cross ties installed
• 4,402 miles of track surfaced
• 27,661 bridge ties replaced
• 547 panel turnouts built and replaced
• 1,476 miles of track ballast cleaned
• 84 bridges replaced or structurally rehabilitated
• 20 D&C infrastructure projects completed
• 75 culverts installed
• 24,870 thermite welds
• 13,294 flash butt welds

Communications and Signals

• 28 signal cut-ins completed
• 302 switch machines replaced
• 369 Centralized Traffic Control (CTC) to Integrated Train Control and Management System (ITCMS) cut-ins completed

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.