One of the most high-profile projects in North Carolina, the I-40/440 project reconstructed 11.5 miles of interstate along the southern leg of the Raleigh Beltline. Most of the roadway was more than 30 years old and crumbling due to an alkali-silica reaction (ASR) between the aggregate and the cement. The design-build project replaced the pavement and included minor widening, providing a safer surface.
Teamed with Granite Construction, RS&H served as the prime design consultant and provided several design innovations that helped to reduce costs and ease public concerns. One of the most significant design solutions included replacing the recommended grass median with a median barrier section, which provided an additional third lane in each direction during construction to increase capacity and ease gridlock.
Although NCDOT had estimated a project cost of more than $190 million, the design-build team was able to shave more than $50 million from the project costs due to innovations and cost savings strategies. Ultimately, the project was an improvement for motorists and sustained this economic lifeline for the state.