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'A Once-in-a-Career Event': NCDOT Officials Tackle I-40 Rebuild After Helene

The $1.36 billion project includes a 30-foot-thick retaining wall reinforced with bedrock to prevent future flood damage, with construction expected to continue through 2028.

  • Nearly a year after Hurricane Helene washed out a seven-mile section of Interstate 40 in the Pigeon River Gorge, NCDOT engineers say permanent construction will start later this year with completion slated for 2028, while one lane each way has been open since March.
  • Because washouts reached mile marker five, lanes between the Tennessee state line and mile marker five were disrupted, prompting a rebuild officials say is unlike anything the state has attempted on Interstate 40.
  • To stabilize slopes, crews have installed more than 128,000 square feet of soil nail walls, built a causeway along the river, and constructed two temporary bridges for material movement.
  • Officials say partial reopening with one lane in each direction has maintained traffic flow as reduced speed limits continue while work progresses.
  • The rebuild carries a $1.36 billion price tag, funded largely through federal emergency relief dollars approved by Congress, and engineers say it will withstand a storm like Helene, with Wesley Grindstaff calling it "pretty special".
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WTVC broke the news in on Thursday, August 28, 2025.
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