Pick-Carry-Place in Concert by Master Operators
- Winter 2025/2026
- Cranemasters
Challenge:
Replace Giant Retarders in Under Two Days
On July 7–8, BNSF Railway executed a 44-hour capital project at its Galesburg, IL classification yard—its second largest in the network and one of the busiest in the country, processing nearly 1,900 cars per day.
The project required months of planning with contractors and organizations across the nation. A critical piece was the replacement of a master retarder and a Group 5 retarder—equipment essential to controlling car movement in a hump yard.
Because all cars roll through the master retarder, replacing it meant shutting down the yard for two days—a costly operation. To minimize disruption, BNSF coordinated numerous maintenance projects during the same 44-hour window. Success depended on completing each element with precision and efficiency.
BNSF Railway
One of North America’s largest freight railroads. Operates more than 32,500 route miles in 28 states
Galesburg Yard
One of the nation’s largest classification yards
Capital Improvements by all service providers during the 44-hour shutdown
- Master Retarder Replaced
- Group 5 Retarder Replaced
- North Scale Wall Rebuilt & Foundation Repairs
- New Approach Plates & Rail Installed on Scale & Approaches
- 11 Turnouts
- 1,672 Ties Installed
- 21,856 ft. of Rail Installed
- 8,891 ft. of Track Lifted
- 19,008 ft. of Shoulder Ballast Cleaned
Cranemasters
BNSF selected Cranemasters to handle the retarder replacements for its proven expertise and the unique capabilities of its 200 RS Super-Duty cranes.
Cranemasters is a leader in heavy-lift rail operations, specializing in retarder replacements, derailment recovery, and precision crane work.
Cranemasters’ Solution:
Heavy Lifting in Perfect Synchronization
Two-Crane Precision
- Cranemasters removed and installed the Group 5 retarder (72 feet long) first, allowing more preparation time for the master retarder foundation.
- Navigating the 600-foot carry path required lifting and walking around switches, substations, multiple tracks, and overhead lines.
- Cranemasters demonstrated advanced two-crane coordination, maneuvering a 90-degree turn.
Three-Crane Challenge
- The master retarder (181 feet, ~180,000 lbs) required three cranes operating in perfect unison to prevent flexing or warping.
- Each crane used 10-foot lift beams with four pick points to evenly distribute weight.
- Crews protected tracks with steel-reinforced wooden blocks, moving them in step with the cranes.
Cranemasters’ 200 RS Super-Duty Advantages
- Lifts and carries up to 100 tons from one side.
- Walks in any direction, rotates 360°, and telescopes up to 53 feet.
- Assembles in 30 minutes—unlike larger cranes that require days of setup and disrupt operations.
- Ideal for projects with confined spaces, overhead obstructions, or complex carry paths.
Expert Coordination
Three superintendents oversaw operations, with each crane crew comprising an operator, a ground crew, and a superintendent. A lead Crane Master ensured synchronized movements, making complex multi-crane operations possible.
Result:
Both Retarders Replaced. Ready to Roll.
In under two days, starting Monday, Cranemasters successfully supported BNSF in replacing both retarders and completing a lengthy list of capital improvements. By Tuesday evening, the Galesburg yard was back online, processing nearly 1,900 cars per day.
- Master retarder replaced (181 ft, 180,000 lbs)
- Group 5 retarder replaced (72 ft)
- Safe navigation around yard infrastructure without damage
- Execution completed within the 44-hour project window
