BNSF Railway has outlined a nationwide rail infrastructure construction and renewal program for 2026, with $3.6 billion allocated across track rehabilitation, yard expansions, and new intermodal facilities.

The Class I railroad’s capital plan places a strong emphasis on heavy rail maintenance and infrastructure construction, with the majority of funding directed toward rebuilding and upgrading its existing network to improve reliability and capacity.

Network-wide track construction and rehabilitation

The largest portion of the 2026 capital program—$2.8 billion—will be allocated to maintenance works, which BNSF says will involve extensive physical construction activity across its rail system.

Planned works include:

Replacement and upgrading of rail and track infrastructure

Ballast renewal and track undercutting

Replacement of approximately 2.5 million rail ties

Installation of more than 400 miles of new rail

13,000 miles of track surfacing and undercutting work

The program represents one of BNSF’s most extensive rail rehabilitation efforts, involving continuous construction along active freight corridors to extend asset life, reduce service disruptions, and maintain network capacity.

Yard expansions and intermodal construction projects

Alongside maintenance works, $358 million of the 2026 capital plan is earmarked for expansion and efficiency projects, supporting customer growth and increasing network throughput.

Major construction activities include:

Continued property acquisition and development for the Barstow International Gateway project in California

Development and the start of construction works for a future intermodal facility in the Phoenix area

Track expansion projects at Galesburg, Illinois, and Winslow, Arizona, aimed at increasing yard switching capacity and improving operational efficiency

These projects add to more than $2.6 billion BNSF has invested in expansion works over the past five years and signal continued demand for rail construction, civil works, and supporting infrastructure services.

Focus on long-term infrastructure performance

BNSF President and CEO Katie Farmer said the capital program is designed to modernize the railroad’s infrastructure while preparing the network for future growth.

“Our 2026 capital plan focuses on strengthening and modernizing our network so we can continue to meet our customers’ evolving needs,” Farmer said.

While not all of the capital spending is directed toward new-build projects, the 2026 plan positions rail construction, rehabilitation, and facility development at the center of BNSF’s infrastructure strategy, with work scheduled across multiple states and freight corridors throughout the year. Additionally, BNSF’s 2026 capital investment plan joins a growing list of major rail modernization projects across the United States.

BNSF Railway 2026 Capital Investment Plan

Overview

Project: BNSF Railway 2026 Capital Investment Program

Project Type: Network maintenance, expansion, and modernization program

Total Investment: $3.6 billion

Maintenance Budget: $2.8 billion

Expansion/Efficiency Budget: $358 million

Track Surfacing/Undercutting: ~13,000 miles

Rail Tie Replacement: 2.5 million ties

Rail Replacement: 400+ miles

Major New Facilities: 2 (Barstow, Phoenix)

Yard Expansions: 2 (Galesburg IL, Winslow AZ)

Infrastructure Investment Breakdown

Maintenance Program: $2.8 Billion (78% of total budget)

Primary Objective: Maintain network in optimal condition, minimize unscheduled outages, maximize capacity

Key Components:

Rail Replacement: Over 400 miles of rail replacement across network

Track Surfacing/Undercutting: Approximately 13,000 miles of track work

Rail Tie Replacement: 2.5 million ties to be replaced

Ballast & Foundation: Track bed stabilization and drainage improvements

Rolling Stock: Locomotive and railcar fleet maintenance programs

Expansion & Efficiency Projects: $358 Million (10% of total budget)

Strategic Context: Builds on $2.6 billion invested in expansion over previous five years

Major Facility Projects:

Barstow International Gateway (California)

• Completing property acquisitions
• Continuing development activities
• Future intermodal capacity expansion
• Strategic California logistics corridor enhancement

Phoenix Area Intermodal Facility (Arizona)

• Continuing development phase
• Starting construction activities
• New intermodal terminal
• Supports Southwest regional growth

Major Line Expansion Projects:

Galesburg Yard Expansion (Illinois)

• Track capacity additions
• Increased switching capacity
• Improved network service performance
• Enhanced railcar and locomotive productivity

Winslow Yard Expansion (Arizona)

• Track infrastructure additions
• Switching capacity enhancement
• Support for transcontinental traffic flows
• Asset productivity improvements

Maintenance Construction Methods:

• Continuous welded rail installation
• High-production track surfacing equipment deployment
• Tie gang operations across network
• Ballast undercutting and renewal operations
• Year-round maintenance windows with seasonal optimization
• Night and weekend work where feasible

Maintenance Program Strategy

Inspection & Monitoring:

• Regular geometry car inspections
• Ultrasonic rail testing for internal defects
• Visual inspections by maintenance crews
• Predictive analytics for prioritization

Component Lifecycle Management:

• Data-driven replacement scheduling
• Condition-based maintenance protocols
• Asset tracking and inventory systems
• Quality control and testing programs

Reliability & Capacity Goals:

• Reduce unscheduled service interruptions
• Maintain consistent track geometry standards
• Prevent derailments through proactive maintenance
• Preserve network capacity and design speeds
• Minimize maintenance-related delays

Operational Benefits: Infrastructure Performance

Enhanced safety through reduced derailment risk

Improved service reliability with fewer outages

Maintained network capacity on existing infrastructure

Better railcar and locomotive productivity

Reduced congestion at key switching locations

Customer Service Impact:

Improved on-time performance

Enhanced network velocity

Greater capacity for volume growth

More predictable transit times

Reduced equipment cycle times

Strategic Alignment

Preparation for anticipated customer growth

Modernization of existing infrastructure

Strategic capacity additions in growth markets (Southwest, California)

Enhanced intermodal capabilities

Extended asset life through proper maintenance

Optimized fuel efficiency via track condition improvements

Support for freight mode shift to rail