At Greenbrier we focus on practical innovation that solves real challenges across the rail industry. One of the most persistent issues involves boxcar doors. Because boxcars are typically loaded and unloaded by forklift, their doors frequently sustain heavy impacts during daily operations. Over time this damage can force railcars out of service, causing delays and reducing equipment availability across the rail network.
Today there are more than 114,000 boxcars operating in North America and at any given time an estimated 9,300 boxcars are removed from service due to door damage. Since forklifts are commonly used for loading and unloading impacts on doors are difficult to avoid. In many cases a boxcar door must be replaced rather than repaired. On average boxcar doors are replaced four times during a railcar’s lifetime.
Addressing a Widespread Operational Challenge
To address this challenge we developed Greenbrier Titan Series Doors™, a new generation of boxcar doors designed to improve durability, reliability and operational efficiency.
Titan Series Doors™ help address this challenge by improving impact resistance and reducing the likelihood of damage. Stronger doors allow railcars to remain in service longer which improves equipment availability across the rail network. According to a 2024 internal repair model Titan Series Doors™ can reduce average lifetime plug door repair-related costs by 55 percent compared with regular steel boxcar plug doors.
These improvements benefit railroads fleet operators and shippers. When fewer railcars are removed from service more equipment remains available to move freight efficiently. The impact is particularly important in shared fleets, where large groups of boxcars serve Class I and short-line railroads across North America.
A Stronger Solution for Boxcar Doors
Titan Series Doors™ use an innovative formula for high-strength lighter-weight steel developed by U. S. Steel. Built from Grade 100 weathering steel, these doors provide twice the yield strength of a traditional boxcar door. For applications requiring even greater strength, they can also be produced using Ultra-High-Strength Grade 175 weathering steel.
Despite the stronger material, the doors maintain a classic boxcar door design and use our standard door mechanism. This allows Titan Series Doors™ to be installed on any new or existing 60-foot boxcar, making them a flexible solution for railroads and fleet operators.
Titan Series Doors™ also include all associated parts including replacement hasps anti-spin and anti-drift devices and our patented worm drive system.
At Greenbrier we continue to invest in solutions like Titan Series Doors™ that strengthen railcar durability improve operational reliability and support a more efficient rail transportation network.
