As a key transportation corridor for the East Coast, I-95 plays a critical role in moving goods and travelers to their destinations. However, one particularly congested segment between Dunn and Fayetteville, North Carolina, had endured over 50 years without substantial upgrades, resulting in bottlenecks and outdated infrastructure.
In late 2019, work began on a transformative $400+ million design-build project to modernize this stretch of I-95, which serves nearly 60,000 vehicles daily. The North Carolina Department of Transportation (NCDOT) partnered with S.T. Wooten to oversee the effort, focusing on widening the highway and bringing the corridor up to contemporary engineering and safety standards.
Comprehensive overhaul
The I-95 modernization project has focused on doubling capacity between Exits 55 and 72, expanding the highway from four lanes to eight. Initial construction on a three-mile segment was designed by the NCDOT, while S.T. Wooten collaborated with RK&K Engineering to plan and construct the remaining 15 miles.
In addition to widening the roadway, construction has involved significant structural enhancements. The S. T. Wooten team has built 13 bridges to meet modern engineering standards. Upgrades include the replacement of nine existing bridges over I-95, one new bridge over I-95, two new bridges that have replaced old undersized box culverts, and lastly a new single bridge along I-95 replacing two older bridges. On top of the bridge work the project required, three noise walls have been built and construction of a fourth noise added to the project scope is about to begin very soon.
Stormwater management systems have also been overhauled. Crews have installed ten new culverts: replacing four aging culverts and five existing pipes to improve drainage. Five roundabouts have been constructed at key interchanges and construction of two more will begin shortly. These roundabouts will ease traffic flow for local vehicles entering and exiting the interstate while accommodating the heavy daily traffic.
Overcoming obstacles
Scale and complexity have presented unique challenges for the I-95 job, particularly the need to maintain traffic flow along one of the nation’s busiest highways. Unlike other construction sites, traffic volumes remain consistently high throughout the day, with heavy trucks generating noise and wind that complicate work zone conditions.
To minimize disruptions, phased construction and night shifts have been critical. During early phases, traffic was routed through temporarily-widened inside lanes, while the newly designed outer lanes were constructed. Weather delays, especially in the rain-prone Sandhills region, have also prompted crews to adapt schedules and add shifts to keep the project on track.
Perseverance and safety
While labor shortages have been an industry-wide obstacle for years, they became a heightened concern during the COVID-19 pandemic. However, having anticipated some of the staffing challenges during the previous winter, S.T. Wooten was able to put contingency plans in place to help maximize the schedule for the benefit of the project and the crew members.
Safety has remained a top priority throughout the project, given the heightened risks of working in a heavily trafficked environment. The high noise levels and constant vehicle movement require crew members to always stay vigilant. Crews are trained to maintain a high level of awareness in the busy work zone, where efficient equipment set-up and breakdown minimize disruptions to traffic.
To enhance both worker and driver safety, the project utilized a Smart Work Zone. Equipped with digital sensors, cameras, speed limit signs and real-time message boards, the system monitors traffic conditions, alerts emergency services to incidents and keeps drivers informed. Strong communication between crews has also been instrumental in reducing work zone risks, ensuring that everyone remains safe as progress continues.
Enhancements to the plan
While the original scope of the I-95 project is nearly finished, the NCDOT has added new tasks and change orders that have extended the deadline for completion. These adjustments are common in large-scale infrastructure projects and reflect efforts to refine details and ensure the best outcomes for the public.
Redesigns for roundabouts at Exits 58, 61 and 65 were completed in 2024, adding a new roundabout at the southbound Exit 58 ramp. Plans have also been finalized for a noise wall at the southern end of the project along northbound I-95 near White Plains Drive. The expanded scope has pushed the completion date from May 2024 to December 2025, ensuring the upgraded highway exceeds modern standards.
Finish line in sight
Successful execution of the I-95 project is a testament to the collaborative efforts of S.T. Wooten’s crew members, NCDOT officials and more than 20 subcontractors. Despite facing challenges, the team’s dedication and innovative problem-solving have kept the project efficiently moving toward completion later this year.
Once finished, the expanded I-95 stretch will provide a safer, more efficient route for travelers. The upgrades will alleviate congestion, improve emergency response times and accommodate growing transportation demands. The project team is ultimately leaving a lasting legacy, one that will have a positive impact on this vital corridor for generations to come.
