Norfolk Southern commissioned R. J. Corman to restore the line, which required rebuilding the rail infrastructure in a challenging environment defined by steep grades, narrow access, and unstable terrain. The scope of work included both embankment repairs at the base of the mountain and long-term structural stabilization at higher elevations to ensure safe, reliable operations moving forward.

At lower elevations, crews rebuilt roadbed and repaired multiple washouts on both the east and west sides of the alignment, restoring the track foundation in compromised areas. Higher on the mountain, work focused on slope stabilization through the construction of various retaining walls and the placement of riprap to improve drainage and control erosion. In total, approximately 179,000 tons of rock were brought in and placed throughout the corridor to rebuild embankments and reinforce stabilized sections. 

Civil and track activities included clearing trees, excavation, embankment stabilization, replacement of ties and rail, and precision tamping and regulating to restore operational integrity. In the most demanding locations, crews installed rail pile, H-pile, and micropile systems, reinforced with sheet piling, tie-back anchors, and through rods, and then backfilled and compacted the systems to stabilize the roadbed and shoulder. Walking surfaces were also replaced to improve durability and long-term accessibility. The project was supported by a large fleet of equipment, including excavators, dozers, loaders, rotary dumps, compactors, and support machinery.

Due to evolving site conditions, the work was executed using a “build as you go” approach that required close collaboration with Norfolk Southern. Designs and quantities were adjusted as conditions were uncovered, including modifications to retaining wall systems and the use of alternative roadbed section mixes to improve constructability and structural performance. Micropile wall systems were incorporated in select locations to provide an efficient and cost-effective stabilization solution.

The project maintained an average workforce of approximately 30 to 35 employees and was completed with no recordable project-related injuries despite steep grades, wet weather, remote work areas, and limited cellular service. Environmental protection was a priority throughout construction, with crews working near creeks and streams under nationwide permits and implementing additional precautions to protect surrounding waterways.

The Old Fort Project is among the largest undertaken by R. J. Corman Railroad Services in the company’s history. Construction was completed in March 2026, at which point a geometry car was run over the corridor, identifying zero defects. The line then returned to service with the operation of the first revenue freight train over the recovered track on April 18th, 2026. The project restored a vital rail connection through Western North Carolina and delivered long-term infrastructure improvements in one of the region’s most challenging rail environments.