Case Studies

Metals Production Facility

Rutherford County, North Carolina

Horsehead Corporation's selection of a greenfield site in rural Rutherford County, North Carolina was driven in part by the fact that the site had very good access to CSX's mainline corridor.  The site did present its challenges as the topography of the site as well as the proximity of a long mainline curve along the site required some creative solutions to providing access to this heavy manufacturing facility that would produce 150,000 tons of zinc per year.  CivilSmith, LLC teamed up with Creative Rail Solutions, LLC to provide a wide range of services to include preliminary design, the Preliminary Engineering Report for grant funding, detailed rail design, rough track roadbed grading design, track construction specifications, bidding and contract documents, and construction observation services.

CSX Mainline & Greenfield Site

CivilSmith and Creative Rail Solutions coordinated with numerous other design team members, Horsehead Corporation, NCDOT, and CSX throughout the entire duration of the project to develop rail designs that met the rail capacity needs of this heavy industrial process while meeting the strict design requirements of CSX.  This project was partially grant-funded and as such required meticulous development of bidding and contract documents that met the requirements of both Rutherford County and NCDOT.

CSX Mainline & Site After Development

Project Highlights:

  • 13,000+ Track Feet of Sidings, Yard, and Service Tracks
  • 20 Industrial Turnouts
  • 2 Mainline Power-Operated Turnouts
  • Rail Scale
  • New Highway Overpass by NCDOT
  • Retaining Wall for Elevated Yard Tracks
  • Concrete Panel Grade Crossing

Service Tracks and Storage Yard - Near Completion

Parallel Staging / Switching Sidings Along CSX Mainline

Mainline Power-Operated & Signalized Turnouts at CSX Mainline

Plant in Full Operation

Aerial Image of Completed Track Construction (Photo from Horsehead Corp.)

Civil / Site Design:  Odom Engineering

Track Construction:  STX Corporation

Track Roadbed Grading: Clary Hood