ArcelorMittal Liberia’s Railway Expansion and Rehabilitation Project

Exclusive Publication by Railways Africa Magazine: an in-depth look at ArcelorMittal’s Liberia Railway Project.

AML currently operates a fleet of 410 gondola wagons, with plans to increase to 540 by the end of 2024. Current fleet of locomotives includes; 13 ES44AC Wabtec locomotives, used on the mainline, and 2 Dash 8 locomotives used for shunting. The ES44AC locomotives feature a powerful 4,400-horsepower engine, a robust AC traction system, and innovative electronics to enhance performance and reliability. As part of the ramp-up plan, AML recently acquired 9 new ES44AC locomotives, bringing the total to 13.

ArcelorMittal’s commitment to Liberia dates back to the early 2000s, following the end of the country’s prolonged civil war. As one of the first major foreign investors in Liberia, ArcelorMittal made significant strides in rehabilitating the nation’s mining infrastructure, with a particular focus on redeveloping old mines and the essential railway system that supports iron ore transportation.
Originally constructed by the Liberia Swedish Mining Company (LAMCO) in the early 1960s, ArcelorMittal Liberia now operates a single-track, standard-gauge (1435 mm) railway extending from the port of Buchanan to the iron ore mine at Tokadeh in Nimba County. This railway spans 245 km in route length, with a combined track length of approximately 280 km, incorporating nine sidings (seven for crossing trains and two for parking maintenance equipment).

ArcelorMittal’s entry into Liberia marked a significant milestone in foreign investment aimed at reviving the mining sector. By 2011, the company began direct shipping of iron ore, initially starting with one million tonnes and steadily increasing to about four million tonnes annually. This ambitious venture required extensive rehabilitation of the mines and surrounding region, including the railway infrastructure, which plays a critical role in ore transportation. The railway underwent comprehensive rehabilitation between 2007 and 2012 by ArcelorMittal’s contractor, Odebrecht Construction International. This upgrade was designed to accommodate an axle load of 30 tonnes and a maximum speed of 70 km/h.

During the rehabilitation process, all wooden sleepers were replaced with similar ones (7”x9”x8’6”) sourced from the USA. While most of LAMCO rails were retained in straight sections, all worn-out rails on sharp curves, turnouts, and bridges were replaced with new 136RE rails from ArcelorMittal Gijon in Spain. The new 136RE rails were delivered in 12-metre lengths and joined using exothermic welding. The railway infrastructure comprises 655 corrugated metal culverts, eight steel bridges, 12 concrete bridges, and seven overpass bridges.

Since the completion of the rehabilitation in 2012, ArcelorMittal Liberia’s rail maintenance team has maintained the rail infrastructure to meet business requirements. Ongoing efforts include replacing worn-out rails, particularly in curves, and transitioning between 132RE and 136RE profiles. Maintenance activities also involve vegetation control within a 7-metre corridor along the railway, surfacing and alignment, and ballast maintenance.
Noteworthy projects include the extension of a siding at Kitoma and the installation of the south turnout in 2018. Seven wayside detectors have been strategically installed to detect failures in rolling stock wheels. Additionally, the construction of a Wye track (triangular joining arrangement) at Green Hill Quarry has been recently completed.

In recent years, ArcelorMittal re-signed the Mineral Development Agreement with the Liberian government, aiming to significantly expand its operations. In readiness for ArcelorMittal Liberia’s Phase II operations, the entire railway is undergoing major refurbishment to restore it to its full design speed.

Key areas of focus include:
1. Expanding capacity to approximately 30 mtpa
2. Rehabilitating all nine sidings
3. Replacing all timber sleepers with steel sleepers
4. Procuring 500 additional wagons and nine new locomotives

Regarding the steel sleepers, this involved the production of sleeper bars meeting British standards, developed and supplied in collaboration with voestalpine VAE SA, a South African company. The sleeper bars were manufactured by ArcelorMittal in South Africa, with 600,000 units being supplied for the entire length of the track. Installation of the sleeper bars has been ongoing since mid-last year, with completion expected by the third quarter of 2024.

Currently, the refurbished railway is dedicated solely to freight, primarily transporting iron ore from the mines to the port. There are ongoing discussions and assessments to explore the potential for passenger services; however, as of now, the railway remains focused on supporting mining operations. In addition to railway refurbishment, the project includes significant port upgrades, such as constructing a new multipurpose quay, rehabilitating the existing berth, and implementing other infrastructure enhancements designed to streamline the export process.

The construction of a new material handling terminal at the ArcelorMittal Liberia Buchanan Port is well underway, along with the development of a rail car dumper, stacker, reclaimers, and a ship loader capable of handling up to 10,000 tonnes per hour.