All lanes of Helene-damaged I-40 to reopen by end of 2029 at cost of $2.8B: NCDOT estimates

HAYWOOD COUNTY, N.C. (WSPA) — North Carolina transportation officials said a stretch of Interstate 40 damaged by Hurricane Helene could fully reopen by the end of 2029.

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New estimates from the North Carolina Department of Transportation released Wednesday show that the cost to reconstruct the interstate is around $2.8 billion.

A previous estimate pinned reconstruction costs at about $2 billion. NCDOT cited new geotechnical information including deeper bedrock in certain areas, increasing costs and timelines to repair.

Construction crews work to reconstruct Interstate 40 in the Pigeon River Gorge in Haywood County, N.C. (From: NCDOT)

“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,” said NC Transportation Secretary Daniel Johnson. “We are rebuilding while we continue to investigate and design, which means our understanding of the work becomes more precise as construction advances.”

Around five miles of Interstate 40 were severely damaged or destroyed in the Pigeon River Gorge in September 2024 during Hurricane Helene.

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Crews are using multiple methods to rebuilt the stretch of highway which is nestled between a steep mountainside and the Pigeon River.

Roller-compacted concrete walls, interlocking pipe pile walls, and other elements are in the process of being constructed to help the future roadway withstand the same forces which destroyed the previous roadway.

Construction crews work to reconstruct Interstate 40 in the Pigeon River Gorge in Haywood County, N.C. (From: NCDOT)

NCDOT also said that they hope to have three lanes open through the Pigeon River Gorge by the end of 2028, two westbound lanes and one eastbound lane.

“Our team continues to examine opportunities to expedite schedules and minimize costs within the design, construction methods, materials and sequencing without compromising the long-term resilience of the interstate,” said NCDOT Engineer Wesley Grindstaff said. “We are reconstructing it to withstand future extreme weather and reduce the risk of another catastrophic failure.”

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