I-40 / I-440 Reconstruction – I-5338/I-5311 “Fortify” Design-Build

The NCDOT “Fortify” design-build project consists of the I-40 / US 64 pavement reconstruction from Jones Franklin Road to I-440 / US 64 and the I-440 / US 64 pavement reconstruction from I-40 / US 64 to north of US 64 / US 264 (Knightdale Bypass) in Wake County. The project is approximately 11.1 miles long, and the primary purpose is to replace the pavement structure. The southern portion of I-40/I-440 is 30 years old and in need of repairs. More than 100,000 vehicles travel this stretch of highway each day, putting a great deal of stress on the road’s surface.

S&ME served as the lead Geotechnical firm during both the design and construction phases of the design-build project. Responsibilities during the design phase of the design-build project included:

  • Alternate Technical Concept (ATC) development and implementation.
  • Geotechnical investigations and design recommendations for six multi-span bridges
  • Mechanistic Empirical (ME) Pavement optimization and design.
  • Mainline and Y-line roadway design recommendations.
  • Temporary structures design recommendations.

During the construction phase, S&ME is providing Quality Control services for asphalt production for over 1,000,000 tons of asphalt. S&ME established and is operating a portable asphalt Quality Control laboratory adjacent to the on-site asphalt plant and is responsible for all-asphalt QC testing. In addition, S&ME is providing Quality Control sampling and testing for on-site aggregate production. S&ME technicians retrieved aggregate samples from the on-site concrete pavement crushing operation and performed gradation and liquid limit testing.

S&ME has also provided the following support services during both the design and construction phases of the “Fortify” project:

  • High Speed GPR of pavement
  • Investigation of existing shoulders for VE proposal
  • CSL / PDA Testing
  • Drilled shaft inspections
  • Dispute and repair consultation for drilled shafts
  • Asphalt mix designs (Virgin, RAP, RAS)
  • Temporary bridge pile inspection
  • Air quality permitting of asphalt plant
  • Hydro demolition permitting and testing
  • Phase 1 and 2 Studies of asphalt plant site