I-40 Gorge Bridges Project

Pigeon River Gorge, North Carolina

Where the Great Smoky Mountains meet the Pisgah National Forest, a series of bridge replacements is transforming a vital stretch of Interstate 40 through one of North Carolina’s most rugged corridors. Tasked with replacing five aging structures originally built in the 1960s, Kiewit is delivering critical infrastructure upgrades in an environment defined by steep slopes, remote access and tight seasonal work windows.

To minimize disruptions to tourism and protect local wildlife, all work is limited to the winter off-season. Traffic remains open throughout construction, requiring careful phasing and lane realignments in areas with limited workspace.

Awarded under the Construction Manager/General Contractor (CMGC) model — a first for the North Carolina Department of Transportation — the project began with close coordination between Kiewit and design teams. This early collaboration allowed constructability and sequencing to be integrated into design decisions, helping mitigate risk and improve delivery.

Each bridge presents its own challenges. On one of the tallest structures, demolition work required specialized containment to protect waterways below. To accelerate progress, crews implemented robotic technology to tie rebar with high precision and speed. On another bridge, the team engineered a custom gantry system to lift and place heavy girders without the use of cranes — an approach that improved efficiency while reducing environmental impact.

Working in a protected mountain ecosystem also called for a range of wildlife accommodations. From constructing bat boxes and timing work around migratory patterns to installing wildlife fencing, jump-outs and crossing corridors, the team developed context-sensitive solutions to balance infrastructure needs with environmental stewardship.

Despite the constraints of terrain, traffic and timing, the project continues to advance through a phased approach that groups bridges by location. Early planning, smart logistics and a dedicated team have kept progress steady and safe.

Built for long-term performance, the I-40 Gorge Bridges project showcases the power of collaboration, innovation and execution in one of the Southeast’s most challenging transportation environments.