NCDOT to Extract Rock from National Forest for I-40 Repairs

WNC --   August 5, 2025:  The long road to recovery for Interstate 40 through the scenic but vulnerable Pigeon River Gorge has taken a significant step forward.

The North Carolina Department of Transportation (NCDOT) announced today that it has received the necessary permits to extract rock from nearby national forest land, paving the way for the full reconstruction of the vital transportation artery severely damaged by Hurricane Helene in September 2024.

The powerful storm caused catastrophic flooding and landslides, most notably washing away significant portions of the eastbound lanes of I-40, effectively severing a crucial link between North Carolina and Tennessee. While NCDOT crews worked tirelessly to stabilize the area and reopen one lane of traffic in each direction by March 2025, the need for a complete rebuild has been paramount.

A key component of this ambitious project is securing a reliable source of rock for construction. After extensive environmental reviews and site assessments, NCDOT identified two locations within the Pisgah National Forest, situated conveniently across the Pigeon River from the damaged interstate. These sites include a nearly 33-acre area designated for stone extraction and an adjacent 11.5-acre site for the temporary storage of overburden material. This material will play a crucial role in the post-construction restoration of the larger extraction site.

The acquisition of permits, including an Individual Permit from the U.S. Army Corps of Engineers and a Water Quality Certification from the N.C. Department of Environmental Quality’s Water Resources Division, marks a critical milestone. These approvals, granted on August 1, 2025, signify that the environmental impacts of the rock extraction have been thoroughly evaluated and mitigated.

“This is a significant step forward in our commitment to fully restoring this vital transportation corridor,” said [Insert Name and Title of Relevant NCDOT Official]. “The ability to source quality rock from nearby locations will not only expedite the reconstruction process but will also be more cost-effective and safer for our crews and the traveling public.”

The proximity of the rock extraction sites is expected to yield several key benefits. By minimizing the distance for hauling materials, NCDOT anticipates a reduction in both construction costs and the overall project timeline. Furthermore, shorter haul routes will decrease the number of heavy truck trips through the existing two-lane temporary traffic pattern in the gorge, enhancing safety for motorists.

With permits secured, the immediate next steps involve the construction of a temporary bridge across the Pigeon River to facilitate access to the extraction sites. Improvements to an existing haul road will also be undertaken to accommodate the movement of equipment and materials. Once these preliminary steps are complete, the work of extracting and processing the rock necessary for rebuilding I-40 can commence.

The reconstruction effort will employ advanced engineering techniques, including the use of roller-compacted concrete and interlocking O-pile walls, to ensure the long-term stability and resilience of the interstate through this challenging terrain. Additionally, NCDOT has implemented new slope monitoring technology along the corridor, providing real-time data on ground movement as a proactive safety measure informed by the lessons learned from Hurricane Helene.

The estimated cost for the I-40 reconstruction is $1.1 billion, forming a significant portion of the approximately $5 billion in total recovery costs projected statewide for road, highway, and bridge repairs resulting from Hurricane Helene. Federal funding is expected to contribute substantially to these recovery efforts.

While a definitive date for the full reopening of I-40 with four lanes remains to be announced, NCDOT is aiming to have two lanes in each direction operational by the end of 2025. Alongside the reconstruction, NCDOT is collaborating with various agencies on a comprehensive long-term plan that includes the restoration of the national forest land impacted by the rock extraction and improvements to wildlife habitat in the area.

WNCTimes

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