Photo by Dillon Daigger

Photo by Dillon Daigger Ed Nebarez of North Platte and Angus Goodwin of Sutherland work on a wheel set, March 30.

Photo by Dillon Daigger A refinished wheel sparkles.

Photo by Dillon Daigger Wheels stacked outside, ready for the scrap yard.

The recently opened Greenbrier Rail Services plant has saved Bailey Yard the expense of hauling damaged wheels out of state for restoration.

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Railcar wheels need to be diligently maintained, because a faulty wheel could lead to a derailment, plant manager Kurtis Olson said.

Until the plant opened in August near Hershey, Union Pacific hauled damaged wheels to a Greenbrier plant in Kansas City.

“With the cost of fuel continually rising, it’s a win-win situation,” Olson said.

Construction of the Hershey plant began in May and it became operational in August, Olson said.

The building covers 50,000 square feet on a 34 acres, a mile east of Hershey, just south of U.S. Highway 30.

When a train is rolling down the tracks, intermittently placed detectors pick up signs of defects in the wheels and electronically alerts U.P. employees. The infrared and ultrasonic detectors can sense overheating and excessive vibrations. Olson said the detectors pinpoint the exact wheel in need of attention.

Then, when a train stops at Bailey Yard for inspection, the faulty wheels are removed and placed on a spur from the mainline, which delivers them to the plant. From there, they are hoisted by crane onto a “re-profiling” line which takes them through an exacting process of restoration.

First, the wheels are washed, sandblasted, and visible flaws are marked. Olson said it’s called “qualifying.” Certified employees evaluate the wheels, measuring the diameter and thickness.

From there, the wheels are placed on a turning lathe which evens out flaws and restores the original luster. The lathe works like a wood lathe, shaving off strips of excess metal.

“The turn lathe is powerful enough to remove up to a half-inch of material in just one cut,” Olson said.

After that, the re-profiled wheels are ultrasonically tested – rotated through a shallow pool of water where ripples point out any invisible irregularities. The wheels may go back to the turn lathe several times until they meet standards.

Next, the wheels are sprayed with a florescent coating and put under a black light. Olson said the coating points out any hairline cracks, which are filed to perfection.

Lastly, the wheels are stacked on a freight car and shipped back to Bailey Yard.

Oftentimes, a wheel on one side of an axle will wear faster than the other, because it is subject to more abrasion around curves.

“The more curvature the tracks have, the more apt wheels are to wear and tear,” Olson said.

Flanges and rims become thinner.

Wheels are particularly subject to damage in an emergency stop or when a brake shoe is accidentally engaged.

The goal at Greenbrier is to make the wheels as symmetrical as possible. Olson said symmetry is more of an issue than flange thickness. If a wheel isn’t properly profiled, it can develop “slid flats,” — grinding rather than rolling on a rail.

If wheels are damaged beyond repair, they are placed on a “new mount” line at the plant, and removed from the axle. Condemned wheels are sold for scrap, but the axle is usually salvageable.

Wheel bearings are always replaced at the plant, regardless of their condition, Olson said.

Greenbrier doesn’t just service North Platte, but also railroad yards from western Colorado to Des Moines, Iowa.

“We wanted to be a good supplier to Union Pacific, particularly North Platte,” Olson said. “We chose this location because of its proximity to Bailey Yard.”

Bailey Yard is the largest railroad yard in the world.

Olson commended the work ethic of western-Nebraskans.

“I’ve been in this field for over 25 years and worked in many locations,” he said. “Here, we have top-notch employees, and I’m not always used to that. The workforce in this area is fantastic.”

Greenbrier currently has 22 employees. Olson said the company plans to steadily expand to around 35 employees so a second shift can start and double productivity.