Project
BNSF Railway
The project posed unique challenges: retrofitting lighting systems without disrupting operations, increasing light levels while reducing energy usage, and ensuring safety for both electricians and rail yard staff. The high-stakes environment, involving billions of dollars in cargo movement, made precise planning and execution essential.
AWL designed and implemented a turnkey LED Conversion Program to meet BNSF’s specific needs. Beginning with detailed energy audits and photometric designs, AWL ensured the upgraded lighting would meet strict IES standards while delivering better visibility for workers. These designs focused on achieving brighter light levels while reducing overall energy consumption. AWL installed long-warranty LED fixtures that could withstand the harsh environmental conditions of rail yards. Each project was managed with a dedicated safety manager, who oversaw daily and weekly safety briefings to ensure a safe working environment for both BNSF staff and AWL technicians. To minimize disruptions, AWL worked around BNSF’s complex logistics and train schedules, completing installations without interrupting operations. AWL’s proprietary project management software provided BNSF with real-time updates, giving the client full visibility into the project’s progress, including before-and-after photos and reports from the field. Collaboration with BNSF’s project management partner, TKDA, ensured the rollout ran smoothly across all 52 locations.
The upgraded lighting has had a transformative impact on BNSF’s operations. Improved light levels have enhanced workplace safety, reducing risks in the hazardous environments of active rail yards, addressing a critical priority for BNSF. The shift to LED lighting has generated significant energy savings, with BNSF reducing its annual energy consumption by 30 million kilowatt-hours and saving over $4 million annually in energy costs. AWL also secured more than $2 million in energy rebates for BNSF, further improving the financial return on investment. In addition to cost savings, the 10-year warranty on the LED fixtures provided BNSF with a durable, low-maintenance solution that virtually eliminated ongoing repair costs. The upgrades also contribute to BNSF’s sustainability goals by lowering
CO2 emissions, a key achievement for the company’s environmental reporting.$4M Saved Annually:
Energy savings from LED
upgrades.$2M in Rebates: AWL
helped secure over $2M in
energy rebates.Enhanced Safety &
Compliance: Improved
light levels reduce
workplace hazards in
high-risk rail yard
environments.10-Year Warranty: LED
fixtures installed come
with a 10-year warranty,
minimizing maintenance
costs.
client
BNSF Railway
Location
National
SERVICE
Lighting Design
MARKETS
Transportation
BNSF Railway, one of the largest freight networks in North America, sought to upgrade lighting across its vast and complex rail yard operations. With 52 sites spanning 15 states, the goal was to improve safety, reduce energy consumption, and support sustainability initiatives. As rail yards are fast-paced, high-risk environments, the project required enhanced light levels to ensure worker safety and compliance with lighting standards, while also significantly lowering maintenance demands.
