The North Carolina Department of Transportation said work on the reconstruction of I-40 through Pigeon River Gorge is ongoing with a new schedule and revised costs, now that engineers have a more complete picture of the ground beneath the roadway.
Based on information gathered during the reconstruction, NCDOT said the cost to replace the corridor is approximately $2.8 billion, an increase over the original estimate of $2 billion. The department said the reconstructed 4-lane roadway is still expected to be complete in late 2029, but that it is continuing to explore opportunities to accelerate the timeline.
“This is the most complex reconstruction NCDOT has ever conducted, and we remain focused on delivering the safest, most durable solution while carefully managing taxpayer dollars,” N.C. Transportation Secretary Daniel Johnson said. “We are rebuilding while we continue to investigate and design, which means our understanding of the work becomes more precise as construction advances. We will continue to be transparent as those estimates evolve, while looking for every opportunity to reduce costs and restore four lanes of traffic as quickly as possible without compromising the long-term resilience of this critical interstate.”
Officials said crews have been able to test from the causeway to determine the depth between the surface of the road and bedrock. Cost and timeframe estimates reflect the project team’s current understanding of the work required and will continue to be refined.
According to the engineer’s results, in some places along the 5-mile-long worksite, the bedrock is exposed, while in others it is more than 50 feet below the surface. Reaching bedrock further below the surface requires longer steel piles, which in turn increased the costs and timeline estimate to complete the repairs, officials said.
The stretch of road along I-40 through the Pigeon River Gorge was severely damaged by Hurricane Helene and in some places was completely destroyed. The roadway is being reconstructed using a combination of roller-compacted concrete walls, interlocking pipe pile walls and associated elements designed to withstand forces that originally damaged or destroyed it.
“History shows us that I-40 in the Gorge is vulnerable to flooding and failure, and not addressing the vulnerabilities now would result in the same damages at some point in the future,” Division 14 Engineer Wesley Grindstaff, who oversees highway operations in the 10 westernmost counties, said. “The cost and consequence of slope failure is very high along this critical transportation corridor.”