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HITACHI RAIL UNVEILS NEW $70M TRAIN FACTORY, TEST TRACK
Page 84 • November 23, 2022 • www.constructionequipmentguide.com • CONSTRUCTION EQUIPMENT GUIDE Hitachi Rail Unveils New $70M Train Factory, Test Track in Hagerstown, Md.
Hitachi Rail unveiled the final designs and images on Oct. 18 for its new $70 million train factory and 800-yd.-long test track soon to be erected on a 41-acre site in Hagerstown, Md.
When fully operational, the manufacturing plant will sustain 1,300 jobs, with up to 460 people working directly for Hitachi Rail on site. The new jobs will command total earnings of $350 million per year and bring major economic benefits to the D.C., Maryland and Virginia region, according to a news release from the company.
Maryland Gov. Larry Hogan joined Hitachi Rail CEO Andrew Barr and other elected officials at the site of the future Hitachi Rail factory, expected to be complete in 2024 along Greencastle Pike in Hagerstown.
“It is exciting to see the new Hitachi Rail factory coming together as the associated economic benefits — including 1,300 jobs — will be an absolute game changer for Washington County as well as the entire region,” Hogan said in his remarks.
“This transformative project is further proof that the Hagerstown region is a major logistical center for rail transportation with unparalleled connections to the northeastern United States and is yet another shining example that Maryland is truly open for business.” Construction Effort On Schedule
The factory’s design presentation included a construction update from Minnesota-based Ryan Companies, the lead site developer. It said that following the project’s announcement in March 2022, the land for the rail plant is now clear, and a concrete deck and the majority of the 248 external concrete walls — each of which is 13-ft.-high, 36-ft.-long, and weighs around 35,000 lbs. — is on schedule.
In total, construction crews will require 1,050 tons of steel to complete the factory building, including joists, girders and structural steel columns. The creation of the facility also will require pouring 12,430 cu. yds. of concrete, enough to fill almost four Olympic-sized swimming pools.
The Hagerstown plant’s manufacturing capability will be enhanced by innovative technological solutions, Hitachi Rail noted, drawing on its century of expertise and global manufacturing heritage to deliver its most advanced digital factory to date.
As a business committed to becoming a climate change innovator, Hitachi Rail also will use the latest techniques to create a factory that uses energy and resources efficiently to protect the environment.
Washington Metro to Get First Order
The train maker added that once complete, the factory will begin work to deliver its first order of 256 new 8000-Series railcars for the Washington Metro service. The contract, announced in March 2021, includes options for up to 800 more railcars to the capital region’s 50-year-old commuter system.
When production is at full tilt, the Hitachi Rail factory will be able to manufacture up to 20 railcars per month in a single shift, with the capability to produce a wide range of trains from metro to high-speed services.
“With construction of our new train $70 million factory on schedule and progressing well, we are one step closer to delivering a new, high-quality fleet for the Washington, D.C., region’s Metro,” explained Barr. “It is exciting to be able to release the final designs of our new facility with its cuttingedge Lumada [data platform] technology. Manufacturing pioneering trains is core to our business, and this factory, with its new workforce, will have the capability to build trains for all North America.”
The 8000-Series Metrorail trains are designed to increase reliability, offer modern on-board technology, and an improved passenger experience. The Metro trains will have popular features that include on-board Wi-Fi, digital screens to provide improved travel information, high-definition security cameras, ventilation system improvements, stringent cybersecurity requirements, heated floors and improved regenerative braking, according to Hitachi Rail.
The all-electric vehicles, with 130 seats per pair of cars, will be a major upgrade when they replace the 2000- and 3000-series fleets, which have been in service since the early 1980s. For the Washington Metro, the new fleet will help improve service for its passengers, be easier to maintain, and reduce costs.
Plant Should Be Boost to Hagerstown Region
The Maryland Department of Commerce and Washington County worked with Hitachi Rail to bring the facility to Hagerstown, Hogan’s office noted. They hope the construction and operation of the factory will be a major economic boost to the area, with nearly 60 percent of the construction value of the plant and test track to be spent with suppliers from across the region.
Small businesses are expected to benefit too, with more than a quarter of the total expenditure anticipated to go to Small Business Enterprises (SBEs). In addition, it is expected that once the company begins to hire in early 2024 and reaches 1,300 direct, indirect, and induced jobs, those earnings will total more than $350 million per year.
Hitachi Rail’s investment in Maryland represents a continuation of its commitment to improve passenger and freight rail transportation in the United States, the company said in a statement. Across North America, the company currently employs more than 1,400 people and has its headquarters in Pittsburgh, Pa.
While the Hagerstown factory will focus on building trains, Hitachi Rail is delivering programs across the entire transportation sector, from major signaling systems to building completely new railways, and supporting rail freight companies nationwide.
Photo courtesy of Hitachi Rail CGI of the Final Design for the New Maryland Factory.
All Island Equipment 39 Jersey St. • West Babylon, NY 11704 631-643-2605 www.allislandequipment.com
ATS Equipment, Inc. 33 Locust Street • Boston, MA 02125 617-825-3600 487 Washington Street, Route 20 • Auburn, MA 01501 508-832-8500 51 Fall River Avenue • Rehoboth, MA 02769 508-379-6200 ww.atsequipment.com
Baschmann Services Inc. 1101 Maple Road • Elma, NY 14509 888-655-1101 www.baschmann.com
Chappell Tractor 454 Route 13 South • Milford, NH 03055 800-698-2640 251 Route 125 • Brentwood, NH 03833 800-616-5666 391 Loudon Rd. • Concord, NH 03301 800-358-6007 www.chappelltractor.com
Highway Equipment Company 615 State Route 33 • Millstone Township, NJ 08535 732-446-7600 www.highway-equipment.com
Westchester Tractor 60 International Blvd. • Brewster, NY 10509 845-278-7766 www.wtractor.com
MAINTENANCE from page 1
These analyses also are indicators of maintenance effectiveness and predictors of potential failures, believes the company. Why, How of Fluid Analysis
Fluid analysis detects problems early, so they can be repaired before they become major failures, said McAllister.
The process helps in scheduling machine downtime and in developing a complete service history for a machine. It improves the opportunity to get top dollar for used machines when the decision is made to offload older rigs through resale or trade-in.
Hand in hand with fluid maintenance goes monitoring equipment condition. It should be an overall part of a contractor’s preventive maintenance plan, said the Caterpillar dealer.
A dedicated program of equipment condition monitoring helps prevent breakdowns and unnecessary repair costs that can rob a company of efficiency and profit.
McAllister’s list of key elements involved in the monitoring process includes advanced fluid diagnostic capabilities that allow the equipment manager to better assess the condition of a rig.
Set Maintenance Schedule
An unexpected breakdown, forcing unscheduled maintenance, can be a huge crimp in a project schedule, especially if the machine plays a major role on the job site.
Poor equipment productivity due to downtime and neglect is a leading contributor to increases in unexpected project costs, believes Phillips66 Lubricants.
Approximately 800 to 900 productive hours annually is what a contractor can expect from a piece of equipment, according to the company, based in Houston, Texas.
“Based on a 40-hour work week that translates at best to a productivity rate of only 62 percent,” Phillips said. “That means most pieces of heavy equipment have a productivity rate improvement window of nearly 40 percent, which can have a big impact” on the bottom line.
Phillips believes one of the easiest and most impactful ways to improve productivity is to adhere to a preventive maintenance schedule for each piece of equipment.
At the same time, a dedicated, fleet-wide preventive maintenance program reduces downtime and increases revenue.
“Preventive maintenance occurs on a pre-determined schedule, regardless of whether the equipment shows problems operating or not,” according to Phillips. “It allows you to identify and address any defects before they can evolve into more expensive and large-scale issues.” Though maintenance tasks will be dictated by an equipment manufacturer’s recommendations and the vehicle itself, most rigs have engines that require similar checks, including: • Engine oil: Use top quality engine oil and other lubricants, advised Phillips66. “Although engine oil represents just a small fraction of your total maintenance costs, it can have a big impact on your bottom line.” Skimping on quality or selecting the wrong type of engine oil can lead to more serious issues, costly repairs,
Using the right amount of lubricant matters. Too little can increase the risk of friction and longer downtime and lower productivity equipment wear, while too much can build up and cause performance issues. later on. “Find the right high-quality oil for your vehicles and keep your equipment running smoothly.” • Fluid levels: Check the coolant, transmission, brake, fuel and other fluid levels, advised the company. Frequent drops in fluids indicate a leak that must be identified and repaired. “As with engine oil, make sure you are using correct type of high-quality fluids to prevent costly repairs.” Among Phillips’ tips for extending the life of heavy equipment is to regularly maintain and service your machines with highquality lubricants. “Regularly inspecting and changing the oil and other lubricants is the most important part of preventative maintenance,” said the company. Because the demands put on a lubricant vary greatly with different components and operating conditions, lubricants have signif-Varying demands put on lubricants require significantly different physical and chemical characteristics. Consistent use of the correct oil maximizes the life and performance of equipment. icantly different physical and chemical characteristics. That’s another reason consistent use of the correct oil maximizes the life and performance of equipment. “Don’t top off with an incorrect oil for convenience,” said Phillips. But using the right amount of lubricant matters too. Too little can increase the risk of friction and equipment wear, while too much can build up and cause performance issues. see MAINTENANCE page 90
Improper Greasing Can Lead to High Temperatures, Noise, Component Failure
MAINTENANCE from page 86 Prevent Equipment Failure
As Phillips sees it, in an ideal world there would never be breakdowns and equipment would operate 100 percent of the time at 100 percent capacity.
A catastrophic failure happens suddenly and causes a rig to cease operation, not only damaging the machine, but causing collateral damage as well.
Equipment continues to operate during a functional failure, but it cannot function according to design specs and likely requires a shutdown to correct the problem.
Understanding the why behind equipment failure can prevent an occurrence. It’s your first line of defense against unexpected equipment downtime, said Phillips.
Surface degradation, consisting mainly of corrosion and mechanical wear of machine parts, results in equipment failure in 70 percent of cases.
Corrosion is particularly problematic in equipment operated in harsh climates or conditions where moisture, dirt or salt can contaminate components.
Water increases the speed at which oil oxidizes, which ultimately leads to the part operating within an acidic environment.
Corrosion of vital industrial parts is among the most common causes of equipment failure, said Phillips.
Mechanical wear — abrasive or adhesive — happens when machine surfaces mechanically rub against each other.
Abrasive wear occurs when particle contaminants, such as dirt or wear debris, cause metal surfaces to become pitted and scored.
Adhesive wear occurs when two surfaces come into direct contact with each other and transfer material from one surface to the other.
To prevent machinery failure caused by surface degradation, keep machinery and internal parts well lubricated and sealed particle contaminant ingress, said Phillips.
The company advises contractors to make sure equipment is well maintained and has parts regularly replaced.
Proper lubrication — using the correct type and amount of oil, grease and fluids — is integral to avoiding equipment failures and to keeping your business running smoothly.
One of the best ways to prevent corrosion and wear, lubrication also protects against heat and contamination and decreases noise in bearings.
“When equipment is properly and regularly lubricated, it has the highest chance of maximum service life,” according to Phillips.
Avoid Improper Greasing
Improper lubrication results from lack of procedures, over- or under-greasing, poor labeling, the wrong lubricant, mixing products and improper handling and storage.
“Without the right technician for the job or the correct procedure, improper lubrication may occur,” warned Phillips.
Over-greasing, the company said, leads to higher operating temperatures and aggressive machine contamination. While highly damaging under-greasing can cause noise, it can go unnoticed in a loud environment.
Correct labelling decreases the risk of cross-contamination and resolves confusion over which lubricants to use.
Applying the wrong lubricant can cause component failures and voids equipment warranty. Mixing products leads to component failures.
“Maintenance personnel need training on the correct ways of handling and installing bearings and using lubricants,” advised Phillips. “Even the most minute particles can enter a small dent and cause contamination.” Key is implementing and adhering to documented lubrication procedures and making sure every technician is properly trained on them. In fact, it is one of the most important things you can do to make sure your equipment is properly lubricated at all times. Another critical step is integrating a labeling system and determining the output of grease guns while calculating the regrease requirements for bearings. Doing so will avoid both over-and underlubrication, and is a great place to start the program, said Phillips66. “Finally, check the owner’s manual to ensure that you are using the OEM-recommended lubricant for each piece of machinery.” Consistently using the correct, high-quality lubricant “is the most important thing you can do to avoid costly equipment failures and to keep your equipment and your business running smoothly.” CEG
Ambrose Equipment / Alta Equipment
1401 Hooksett Rd. • Hooksett, NH 03106 603-644-8787 1 Madison Street • Plainville, MA 02762 508-643-0044 www.ambroseequipment.com
Able Tool & Equipment
410 Burnham Street South Windsor, CT 06074 860-289-2020 www.abletool.net
Admar Construction Equipment & Supplies
1950 Brighton Henrietta Town Line Road • Rochester, NY 14623 585-272-9390 7800 Brewerton Road • Cicero, NY 13039 315-433-5000 449 Commerce Rd. • Vestal, NY 13850 607-798-0333 1394 Military Road • Tonawanda, NY 14217 716-873-8000 2390 Rochester Rd. • Canandaigua, NY 14424 585-396-0031 878 Old Albany Shaker Road • Latham, NY 12110 518-690-0750 3001 West 17th Street • Erie, PA 16505 814-833-7761 121 Armstrong Road • Pittston, PA 18640 570-299-5505 www.admarsupply.com
Cap Rents Supply, LLC 18-25 43rd Street Astoria, NY 11105 718-932-4100 • Fax: 718-932-8971 www.caprents.com
Central Equipment Company P.O. Box 261 45 Dempsey-Greaves Lane • Stillwater, ME 04489 207-827-6193 Fax: 207-827-3774 54 Old Canal Way • Gorham, ME www.centralequipmentco.com
By Brenda Ruggiero
CEG CORRESPONDENT
The Pennsylvania Department of Transportation (PennDOT) continues to move to open a new bridge at the site of the Fern Hollow Bridge in Pittsburgh, Pa., less than a year after its collapse.
The bridge on Forbes Avenue between Squirrel Hill and Point Breeze collapsed on Jan. 28, 2022. Under an emergency grant of $25.3 million from the federal Department of Transportation, PennDOT began work on Feb. 3. The contract was awarded to Swank Construction under the direction of Pete Douglas. Plans are to open the bridge before the end of the year and fully complete the project later in 2023.
The contract includes the bridge collapse demolition and new bridge design and construction.
Doug Thompson, principal assistant construction engineer, PennDOT District 11, said that early on, PennDOT offered to help the city and provide expertise.
“I guess they entered into a legal agreement in the first few days with the city so that PennDOT could take over the design and construction responsibilities for the project, to replace the bridge,” he said.
Jason Zang, assistant district executive, construction, PennDOT District 11, said that they were also talking closely with FHWA in regard to how they could proceed as quickly as possible.
“They basically said what you want to do is pick a contractor and that’s how we did it,” he said. “So, we picked a contractor and we picked a consulting firm right out of the gate and that was I think day one or day two. That was right there after the collapse. In all PennDOT districts, the primary function is putting projects out to bid, so it is kind of our specialty of getting projects out to contract and to bid. None of us want to see that in our career and I hope we never have to see it again, but that bridge carries like 20,000 vehicles a day, I think. The goal was to get the bridge replaced as quickly as possible. That’s always been the goal.”
Thompson reported in late September that the collapse was first cleaned up, restored and wasted, and a concurrent design and construction was begun.
“Actually, the design started about a month before we could start construction because we had to have some plans for the foundations prepared, so right out of the gate they did core borings and started on their foundation design,” he said. “Pretty quickly out of the gate, we narrowed down the construction type. We basically determined the width of the bridge — the bridge needed to be the same that was out there now due to the right of way that the city had through a park and everything.” Once the span configuration was determined, the contractor worked quickly to determine the most quickly available structure type: steel or concrete. Based on cost and availability, pre-stressed concrete I-beams were chosen. “The big driving factor in the schedule was when could the beams be delivered,” Zang said. “We took that date based on when the beams could be delivered and we backed into April … so we weren’t out there just pitter-pattering around. We wanted to be efficient, so there was some time there where there wasn’t much going on on site, but there was a lot of the design work going on. But we based the groundbreaking on when we started our foundation. It was all based on when the beams would show up.”
As the beams were being constructed, the designers were finalizing the columns and pier caps on top of the caisson foundations and designing the abutments. The beams started arriving in on July 25.
“There were some challenges associated with that,” Zang said. “They could deliver two beams a day. Once they came into Pittsburgh, the city coordinated and escorted the beams through the congested areas of Oakland. Oakland’s a pretty busy area, so they escorted the beams through Oakland, we
Another challenge was the protec- got them in and erected two a day for the first two spans. So, tion of what is referred to as “the we had the first 14 beams erected, two a day, and then they gatehouse,” a historic pavilion structure made of stone right at the corner of the bridge. brought in span three from a different direction, not through Pittsburgh but from the eastern side of Pittsburgh through Monroeville and they backed them up the street. That drew a lot of attention when they closed the street and backed them up Braddock Avenue and onto the site.” Next, the contractor arranged for the rental of two large track cranes to erect the beams. The largest came in on more than 50 tractor trailer loads and the other one was on 25 tractor trailer loads. “They erected the Span 2 beams with the large crane that was sitting up on the abutment,” Thompson said. “They erected those Span 2 beams onto Span One and then the next day they had a smaller crane, although it was a very large crane. And they had a smaller crane sitting down in the valley. Then they did a two-crane lift — a dual lift — and one crane picked either end of it while it was sitting on Span One. Then, they both lifted it into position in Span 2 because there just wasn’t a crane available with the radius and capacity to lift the beam from behind the abutment clear out to the center span.” Concerning challenges, Thompson spoke about the effort involved to quickly, concurrently design and construct a bridge and literally start construction when you only have the foundation plan to prove. “Another big challenge I personally have dealt with, like Jason [Zang] said earlier, we’re really good at developing designs and preparing a bid package and putting projects out to bid and contractors bid on a project and give us a price for a bridge,” he said. “But
