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Croton-Harmon Maintenance Facility

Transforming facilities for one of the largest commuter railroads in the U.S.
  • New wheel truing facility—the first in North America to offer tandem wheel lathe for truing two wheel-sets simultaneously-Gannett Fleming

    New wheel truing facility—the first in North America to offer tandem wheel lathe for truing two wheel-sets simultaneously.

  • Phase II included the design and construction of a 12,600-square-foot maintenance facility-Gannett Fleming

    Master plan helps Metro-North Railroad balance improvements with funding.

Metropolitan Transportation Authority Metro-North Railroad

Parsons Brinckerhoff 

Croton-on-Hudson, New York

Our Role
Transit & Rail, Facilities, Planning.

275,000 square feet
Construction Cost
$20 million
4 years 6 months
  • Nearly 100-year-old maintenance yard and shop updated to a modern facility
  • Plan that provides for future improvements, funding, and operations
  • Metro-North Railroad maintains its exceptional record for on-time performance.

As more New York City commuters found their way to the suburbs, ridership on the Metro-North, one of the largest commuter railroads in the U.S., increased. Evolving train set technology meant that Metro-North’s maintenance yard and shop facilities could not properly accommodate the fleet of electric cars, diesel-haul coaches, and locomotives that serve its Hudson and Harlem lines. With portions of its Croton-Harmon Yard and Shop Complex dating back to the early 1900s, Metro-North Railroad was faced with the massive task of updating the facility to ensure reliable trains with smooth and efficient operations for passengers. What’s more, it had to do so without interruption of its daily operations. 

As technical advisor to Metro-North for this design-build project, Gannett Fleming was charged with developing a master plan and designs that would transform the nearly 100-year-old complex into a modern facility featuring three new maintenance buildings, expanded train storage, and new locomotive servicing stations that would keep the maintenance operations ahead of projected demand through the year 2020. Our approach to the project enabled Metro-North to prioritize its reconstruction efforts, remain responsive to its current equipment maintenance operations, and provide for and remain ahead of projected demand.

What We Did

Gannett Fleming developed a strategic master plan to reconfigure the Croton-Harmon Yard and Shop Complex to accommodate a reliability-centered maintenance plan for its new M-7 fleet. Our firm documented the requirements for the new M-7 cars, defined preferred work practices and equipment requirements, and developed floor plans to support the new maintenance programs. A key element of the study involved reconfiguring the existing shop to accept the specialized bench test equipment furnished with the M-7 cars. The master plan provided the framework necessary for Metro-North to manage the difficult and complex tasks of completely replacing, improving, or expanding all equipment maintenance facilities while maintaining full operational capacity. 

Gannett Fleming provided dynamic, multidisciplinary designs for several mixed-facility improvement projects at the complex. We prepared the design-build construction documents for a new wheel-truing facility, the first in North America to offer a tandem-wheel lathe for truing four wheels simultaneously; the construction documents for repairs and renovations to the main shop; and the study and design of facility modifications and improvements to support the railroad’s new fleet of M-7 electric cars. We also prepared the design-bid-build documents for repairs and renovations to the complex’s equipment maintenance facility, with improvements that included roof and façade repairs, plumbing renovations, and compressor replacements.

Key Features

  • Three new state-of-the-art equipment maintenance facilities
  • Expanded train storage capacity
  • New locomotive servicing stations
  • The first wheel truing facility in North America to feature a tandem wheel lathe for truing four wheels simultaneously.

Awards & Recognition

  • Design-Build Project of the Year, 2008, American Society of Civil Engineers, Metropolitan Section Awards
  • Gold Award, 2008, American Council of Engineering Companies of New York, Engineering Excellence Awards
  • Ward House Award, 2008, American Society of Civil Engineers Lower Hudson Valley Branch, Lower Hudson Valley Branch Annual Awards
  • Project of the Year, 2007, Design-Build Institute of America, DBIA Annual Awards.

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