Amtrak has halted its popular Borealis passenger rail service between St. Paul, Minnesota, and Chicago, Illinois, replacing trains with buses after discovering corrosion in its Horizon railcars during a routine inspection. The suspension, announced on 26 March, follows a banner period for the route, which surpassed 100,000 passengers in just 22 weeks since its launch in May 2024. The decision affects multiple Amtrak lines and underscores challenges with ageing equipment, though the company is working on a long-term fix.
Amtrak’s official statement, released on 26 March, detailed the issue: “In compliance with federal requirements and its ongoing commitment to safety, Amtrak routinely inspects its railcars and locomotives. We discovered corrosion in several Horizon railcars and, while working with the manufacturer, decided to remove the equipment from service after learning of additional areas of concern from intensive inspections of multiple cars.” The Horizon fleet, built by Bombardier (now Alstom) between 1988 and 1990, includes just over 100 cars that have served Amtrak for nearly four decades.
The suspension impacted the Borealis route immediately, with Wednesday’s scheduled trains replaced by chartered buses. According to MPR News, the corrosion was identified during a standard check, prompting Amtrak to pull the affected cars across several services, including the Hiawatha (Chicago to Milwaukee), Downeaster (Boston to Brunswick, Maine), and Amtrak Cascades (Pacific Northwest). While the Empire Builder, a long-distance train sharing the St. Paul–Chicago corridor, continues unaffected due to its use of different equipment, the Borealis— reliant on Horizon cars—faces an uncertain timeline.
Amtrak has not specified how long the buses will substitute for trains, stating only that it is “developing a long-term plan.” However, a service advisory noted that from 27 March, Borealis operations would resume with Superliner equipment—bilevel cars typically used on long-distance routes—though Business Class passengers will receive refunds for the fare difference, as Superliners lack this option. For now, the daily round-trip service, which departs St. Paul at 11:50 AM and Chicago at 11:05 AM, continues via alternative means.
A blow to a rising star
The suspension comes at a jarring moment for the Borealis, which had quickly become a Midwest success story. Launched on 21 May 2024 as a state-sponsored service backed by Minnesota, Wisconsin, and Illinois, the train doubled Amtrak’s frequency between St. Paul and Milwaukee, complementing the Empire Builder with a midday schedule. Priced from USD 41 one-way, it offered Coach and Business Class seating, a café car with regional fare, and scenic Mississippi River views, drawing praise for convenience and sustainability.
Ridership figures underscored its appeal. RailwayPRO reported that by 24 October 2024, the Borealis had carried over 100,000 passengers in under six months—a milestone celebrated by Amtrak and state officials aboard the trains that day. “We’ve been pleasantly surprised by the excitement and ridership that the new service has created,” said Amtrak President Roger Harris, hinting at plans to boost capacity. Minnesota Transportation Commissioner Nancy Daubenberger added, “Reaching 100,000 passengers in less than six months is a testament to the good things that can happen when we provide a service that is needed.”
The route’s 411-mile journey, clocking in at 7 hours and 24 minutes each way, connected urban hubs with stops like Winona, Red Wing, and Milwaukee. Its first full month (June 2024) saw over 18,500 riders, and by autumn, trains were often full midweek—a rarity that had Amtrak and its partners eyeing expansion. The service’s USD 53.3 million capital cost, funded through federal grants and state contributions, seemed validated by this demand, with annual operating costs estimated at USD 6–8 million split among the three states.
Wider impact and equipment woes
The Horizon recall ripples beyond the Borealis. The Hiawatha, a busy short-haul route, saw half its six daily round-trips shift to buses, while the Downeaster operates with reduced cars, and most Cascades services rely on substitutes. Amtrak’s fleet of roughly 70 Horizon coaches and café cars—single-level units designed for regional routes—faces scrutiny as their age (35–37 years) raises maintenance questions. The company’s statement offered no repair timeline, leaving riders and state partners in limbo.
For Borealis passengers, the switch to buses disrupts the rail experience that drew many. The route’s appeal—spacious seats, Wi-Fi, and a stress-free alternative to driving—takes a hit with road transport, though Amtrak aims to mitigate this with Superliner trains. The Empire Builder’s resilience, using newer or different rolling stock, highlights the vulnerability of state-sponsored routes dependent on older equipment.
The Borealis’ suspension tests a service that had revitalised Midwest rail travel. Its rapid rise—outpacing a 2015 Amtrak projection of 155,000 annual passengers—suggested a robust market, bolstered by USD 38.6 million in federal funding awarded in January 2025 to sustain operations through 2030. Yet, equipment shortages, a known Amtrak challenge, now cloud its future. Plans for a second daily train, under study in Wisconsin, may stall if fleet issues persist.
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