National Highway System (NHS) freight connectors serve as critical links between the mainline NHS and major intermodal terminals. A 2000 Federal Highway Administration report to Congress on the condition and performance of intermodal connectors identified 517 freight-only terminals composed of ocean and river ports, truck/rail, and pipeline/truck facilities. In addition to these freight-only terminals, 99 major freight airports (which handle both passenger and freight) were included in the list of freight intermodal terminals.

The report concluded that connectors to ports have twice the percentage of mileage with pavement deficiencies when contrasted to non-Interstate NHS routes. Connectors to rail terminals had 50 percent more mileage in the deficient category than non-Interstate NHS routes. Connectors to airport and pipeline terminals appeared to be in better condition than connectors to rail terminals; they showed about the same percentage of mileage with pavement deficiencies as non-Interstate NHS. The report also identified geometric and physical conditions of connectors. However, it did not include an assessment of needed improvements or investment requirements.

Supplemental analysis conducted since the release of that report has indicated that approximately one-third of the connector system is in need of additional capacity based on current congestion levels. Of the remaining connector mileage, 469 miles needed pavement or lane width improvements, while 243 miles (roughly 12 percent) have adequate pavement, lane, and shoulder width.

Addressing this backlog of deficiencies would cost $2.597 billion. Improving service to cope with expected increases in freight volumes would cost about $4.291 billion.

An analysis of highway-rail grade crossings on the federal aid highway system by the Federal Railroad Administration finds that all categories of highway users could spend up to $7.8 billion in lost time at grade crossings over the next 20 years. Auto users could spend 123 million more hours delayed at crossings and truckers could log an additional 6.6 million hours behind closed gates in 2022 compared to 2002.

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