Metro-North Railroad identified the Harmon Shop – its largest maintenance facility – as critically outdated and unable to support current and future fleet needs. The decades-long redevelopment program aimed to deliver a modern 400,000-square-foot facility with advanced maintenance bays, multi-level parts distribution and expanded capacity to support reliability and performance goals across the system.
What challenges did STV address?
Across the multiple phases of the program, STV tackled complex issues, including the demolition and replacement of century-old infrastructure, the design of maintenance bays capable of servicing multiple vehicle types (including cars and locomotives) and program delivery within an active rail yard without disrupting operations. The tight site constraints, evolving fleet requirements and integration of new shop functions added layers of logistical and engineering complexity.
What solutions did STV deliver?
Starting in Phase II, STV provided preliminary design, design oversight and construction support for the material distribution center, communications building and new maintenance-of-way facilities. In Phase III, STV delivered preliminary design services for the coach shop and locomotive shop, including train-length maintenance tracks, inspection pits, drop tables and a wash facility, as well as supporting office and parts storage areas. In the final phase (Phase V), STV served as the industrial engineer-of-record for the new 400,000-sq-ft facility; designing service pits, car hoists, pedestal tracks; and multi-level parts distribution corridors to link the electric shop, support shops and consist maintenance.
How does the Harmon Shop redevelopment benefit rail service and the region?
By delivering a state-of-the-art maintenance facility, the Harmon Shop redevelopment enhances Metro-North’s ability to maintain and repair its fleet efficiently, supporting high on-time performance and reliable service for tens of thousands of daily commuters. The facility’s advanced capabilities also prepare the railroad for future rolling-stock variants and maintenance needs, thereby bolstering regional mobility, workforce safety and long-term infrastructure resilience.
Key stats and accolades
- Multi-phase redevelopment spanning more than two decades and five major phases.
- 400,000 sq ft new maintenance and repair facility equipped with a dozen car hoists, four pedestal tracks, door- and roof-level platforms, and multi-level parts distribution corridor.
- The project supports Metro-North’s consistent on-time performance and modern fleet maintenance readiness.
