On August 28, 2013, a significant milestone was achieved in southern California’s freight rail system with the opening of the Colton Crossing Grade Separation. This project, which had been plagued by historic delays, was completed eight months ahead of schedule and saved a staggering $94,000,000. The key to this success was the innovative use of Lightweight Cellular Concrete (LCC) by Cell-Crete.

Located fifty miles east of Los Angeles, Colton Crossing had been a bottleneck since 1883. To address this issue, HDR collaborated with over 20 stakeholder groups to design an impressive 8,150-foot flyover structure. This structure elevated the Union Pacific Railroad’s east/west tracks a remarkable 35 feet above the north/south tracks of BNSF Railway, effectively relieving the congestion in this critical area. The benefits of this project extended beyond the local community, as it facilitated increased freight mobility from the nearby ports of Long Beach and Los Angeles, thereby boosting the national economy.

Designing and constructing this ambitious project came with numerous challenges. One of the primary concerns was ensuring that the mainlines remained operational during the construction process. Additionally, the site presented tight constraints, poor soil conditions, and seismic considerations. However, a solution was found in the form of cellular concrete, a material not previously used in this type of application.

The use of cellular concrete proved to be a game-changer due to its resilience and simplified construction process. This innovative approach eliminated the need to replace low-quality soil with thousands of truckloads of imported fill material, resulting in significant time and cost savings. Furthermore, it reduced the equipment required for construction. As a result, the project was completed more efficiently and with minimal disruption.

Today, the Colton Crossing Grade Separation stands as a testament to the successful integration of freight rail infrastructure and the surrounding community. Instead of imposing large, unsightly retaining walls, the project incorporated decorative walls that reflect the unique character of Colton. This harmonious connection has not only eased congestion, improved air quality, and reduced noise but has also enhanced the overall quality of life for the local residents.

The Colton Crossing Grade Separation project serves as a shining example of how innovation and collaboration can overcome long-standing challenges in the transportation industry. By leveraging the benefits of cellular concrete, this endeavor has revolutionized the way rail infrastructure is constructed, paving the way for future advancements in the field.