Skanska-Fay JV Builds Howard Street Tunnel Modernization Ahead of Schedule

A joint venture between Skanska and Mid-Atlantic builder Fay S&B USA Construction, has reached substantial completion on CSX’s $450 million Howard Street Tunnel modernization project in Baltimore—months ahead of schedule.

The upgrade is part of CSX’s capital improvement program to eliminate clearance restrictions for double-stack trains along the Baltimore-to-Philadelphia corridor. By increasing the 8,700-foot tunnel’s clearance from 19 to 21 feet without damaging its original 1895 brick-and-stone archway, the project boosts freight efficiency for shippers, extends the tunnel’s lifespan, and avoids the disruption and cost of building new infrastructure.

“Delivering this complex project ahead of schedule demonstrates what’s possible when engineering expertise meets strategic vision,” says Keith Chouinard, Skanska Senior VP and GM. “The enhanced freight will improve logistics efficiency for businesses throughout the region and drive measurable economic growth while strengthening the nation’s rail infrastructure.”

The Skanska-Fay JV worked with CSX, lead designer Hatch, and Baltimore-based WRA to engineer a progressive design-build approach. Crews demolished and excavated the tunnel floor, using a custom railcar-mounted gantry crane to install nearly 1,200 precast concrete invert slabs—each 18 to 19 feet wide—forming a new, lower floor. The team operated around the clock for seven and a half months, completing substantial work by mid-September.

“The progressive design-build method and the Skanska-Fay team’s deep experience were key to this project’s success,” says Ryan Surrena, President of Fay. “The teamwork and ingenuity turned a 130-year-old structure into a modern success story.”

The modernization is expected to unlock freight capacity from the Port of Baltimore to Midwest destinations, creating long-term supply chain and economic benefits across the Mid-Atlantic.

In a related project, Fay is also reconstructing Baltimore’s historic North Avenue Bridge — replacing two 19th-century masonry arches with a modern single-span steel girder bridge and concrete deck superstructure.