New York's Subway System Turns 110 — See How The City's Famous Trains Are Made

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Christian Storm/Business Insider

If you live in New York City, chances are you use the subway system daily. Love them or hate them, New York's subway cars are an iconic symbol of the city. But have you ever wondered how those cars came to be? 

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We did, and since today marks the 110th anniversary of our glorious subway system, we thought we would find out.

We took a trip (via subway, of course, as well as Metro-North rail) up to Yonkers, New York, to the Kawasaki Rail Car Manufacturing Facility, where many of New York's subway cars are completed and readied for service. What we found gave us a new perspective on the way we get to work every morning.

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Kawasaki has been making heavy rail cars since 1906. Their Yonkers factory recently celebrated its 25th anniversary. Why Yonkers? An initial contract with the Port Authority for PATH trains stipulated that cars had to have final assembly done within a 25-mile radius of the Statue of Liberty. The building also used to be a Port Authority building.

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The Kawasaki Heavy Rail Factory in Yonkers, NY. Christian Storm/Business Insider

Rolling stock makes up 10% of Kawaski's manufacturing, which includes commuter rail, high speed rail, light rail, and heavy rail. At this site, they do final assembly of brand new cars, as well refurbish older ones.

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Christian Storm/Business Insider
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Kawasaki is the second largest manufacturer of train cars, owning 23.5% of the passenger rail market, just behind Bombardier with 30.1%. The third largest competitor is Siemens. Subway cars are built on contract from various authorities. The Yonkers plant has built and overhauled cars for the Port Authority, LIRR, PATH, SEPTA, and others.

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Christian Storm/Business Insider

At 150,000 square feet, the factory is huge. Over 4,500 cars have been assembled at the plant.

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Christian Storm/Business Insider
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All the parts for the cars are made in-house, using raw materials and man power. Depending on the contract, these parts can include flooring, ceiling panels, wall panels, doors, lighting, seats, wiring, heating, air conditioning, piping, and all underfloor and cab equipment.

Kawasaki Tour
Christian Storm/Business Insider

Sheets of stainless steel are cut into shapes using a laser cutter or are punched out via a large machine. They are then bent and formed by machines and by hand into fixtures for the subway cars.

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Christian Storm/Business Insider
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Christian Storm/Business Insider

The main bodies of the subway cars, known as "shells," arrive at the Yonkers plant on large flatbed trucks from Kawasaki's plant in Lincoln, Nebraska.

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Christian Storm/Business Insider
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Other cars which have been in use and are in need of refurbishing are sent to the factory as well.

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Christian Storm/Business Insider

When they arrive, the cars are placed on a long track in the center of the facility, where they are worked on. You can see that the work platform is two-tiered, allowing workers to install equipment, like air conditioning, in the roof compartment.

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Christian Storm/Business Insider
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This train looks like it might be used for the L or the F lines.

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Christian Storm/Business Insider

On the lower track, workers place wheels, also called "trucks." Just like the shells, Kawasaki works on both brand-new and refurbished trucks. The wheels are 32 inches in diameter and each truck can weigh around 8.5 tons.

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On this refurbished truck, we can see the shoe that connects to the electrified "third rail," giving the truck its power. Each truck is self-propelled using that voltage and also comes with its own airbags.

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Christian Storm/Business Insider

Once both the car and the truck are ready to go, the truck is moved on the lower set of rails, underneath the subway car, and the two are "married."

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The cars go through rigorous testing at each stage of the building process. This machine runs several tests, including one which simulates the full weight of a subway car completely filled to capacity. During each work contract, a "customer" inspector who is designated and hired by the authorities contracting the work oversees the examinations.

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Christian Storm/Business Insider

Cars can also be tested outside on the plants short outdoor testing track, mimicking real subway tracks. Note the factory's proximity to the Metro North railway line, which Kawasaki is able to use for transporting new subway cars as well.

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Christian Storm/Business Insider
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Once a car is complete, it is brought to the end of the track, where two "traverser tables" pick up each truck. The tables are remote-controlled and are used to move the cars to flatbed trucks or to the tracks outside. From there, it's off to the subway system and a long life transporting you all over the city.

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Christian Storm/Business Insider

Now want to know where some of the subways cars go once they're retired?

dont use kamelia
Stephen Mallon

The answer might surprise you...»

New York Transportation Photos
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