Pushing Iron on the Alaska Highway in the 1980s

[MikePhua]

The Harsh Frontier and the Machines That Tamed It
In the early 1980s, the stretch of the Alaska Highway between the Canadian border and Fairbanks was a rugged, unforgiving corridor. Remote, frost-heaved, and sparsely serviced, it demanded not just skilled operators but machines that could endure relentless punishment. This was the era before cushion ride scrapers and climate-controlled cabs—when comfort was secondary and productivity was king.
Crews working this corridor relied on a spread of heavy iron that included Caterpillar 631B scrapers, D9G dozers, 627 paddle-wheel scrapers, and the formidable twin-engine TS-24s. These machines, operated by Stephan & Sons out of Anchorage, represented the backbone of earthmoving in Alaska’s interior. The work was grueling, the fuel consumption staggering, but the results were transformative—cutting grades, building embankments, and reshaping the wilderness into a usable artery.
Caterpillar 631B and the Era of Direct Drive Scrapers
The 631B was a single-engine open bowl scraper introduced by Caterpillar in the late 1960s. With a capacity of around 31 cubic yards and powered by a D343 diesel engine producing roughly 425 horsepower, it was designed for high-volume hauling across long grades. The B-series scrapers featured direct drive transmissions and mechanical steering systems, which required finesse and strength from the operator.
By the 1980s, the 631B was still a staple in large-scale highway and mining projects. Its simplicity made it easy to repair in the field, and its rugged frame could withstand the punishing terrain of Alaska. However, without cushion ride suspension, operators endured bone-jarring impacts, especially when traversing frost boils and glacial till.
The D9G and the Golden Age of Dozing
The Caterpillar D9G, introduced in the mid-1960s, was a 385-horsepower crawler dozer that became synonymous with heavy ripping and push-loading. Equipped with a torque converter and powershift transmission, the D9G offered improved maneuverability over its predecessors. Its drawbar pull and blade capacity made it ideal for pushing scrapers and cutting through permafrost-laden soils.
In Alaska, the D9G was often paired with TS-24 scrapers, helping them load in tight cuts or wet conditions. The dozer’s reliability and brute strength earned it the nickname “the smoker,” a reference to the black exhaust plumes that marked its labor under full load.
The TS-24 and Twin-Engine Earthmoving
The Caterpillar TS-24 was a twin-engine scraper with a front and rear power unit, each producing over 300 horsepower. With a bowl capacity exceeding 40 cubic yards, it was designed for high-production earthmoving in open areas. The TS-24’s complexity required skilled operators and meticulous maintenance, but its output was unmatched.
On the Alaska Highway, TS-24s were used to haul long distances between cut and fill zones. Their ability to self-load and climb grades made them indispensable in remote areas where push dozers were limited. However, their fuel consumption was legendary—burning upwards of 20 gallons per hour under load. Fortunately, diesel was relatively cheap at the time, and fuel trucks were a constant presence on site.
Life on the Spread and the Culture of Iron
Crews working these machines formed tight-knit units, often living in mobile camps or bunk trailers. The term “spread” referred to the collection of machines and personnel assigned to a specific stretch of roadwork. Stephan & Sons maintained one of the most respected spreads in the region, known for its discipline, output, and ability to work through brutal conditions.
Operators often modified their machines for comfort and performance. Homemade cab heaters, extra padding, and custom toolboxes were common. Stories circulated of machines running 24 hours a day during peak season, with operators rotating in shifts and mechanics performing field repairs under floodlights.
A Story from the Ice Fog
One veteran recalled a night near Tok Junction when temperatures dropped below -40°F. A TS-24 stalled mid-haul, and the rear engine refused to restart. The operator, wrapped in wool and diesel-soaked gloves, climbed out and used a propane torch to warm the fuel lines. After 30 minutes of coaxing, the engine roared back to life, sending a plume of smoke into the ice fog. The haul resumed, and the crew finished the cut before sunrise.
Such stories were common—testaments to the grit and ingenuity of those who worked the highway. These weren’t just equipment operators; they were mechanics, problem-solvers, and survivalists.
Lessons for Modern Earthmoving
While today’s machines feature GPS grading, joystick controls, and air-ride seats, the lessons from the Alaska Highway remain relevant:

• Simplicity in design allows for field repair and long-term reliability
  
• Operator skill and mechanical intuition are irreplaceable
  
• Fuel logistics and maintenance planning are critical in remote operations
  
• Team cohesion and shared purpose drive productivity under pressure
  

Conclusion
The Alaska Highway in the 1980s was more than a construction site—it was a proving ground for machines and men. The 631Bs, D9Gs, 627s, and TS-24s that carved through the wilderness were not just tools; they were extensions of the operators who ran them. In an age before electronics and automation, success depended on iron, diesel, and determination. The legacy of those spreads lives on in the roads they built and the stories they left behind.