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  4. NC 540 Triangle Expressway Southeast Extension

NC 540 Triangle Expressway Southeast Extension Design-Build

With the completion of the Triangle Expressway (NC 540), there will be a new, faster and safer option for travelers that helps alleviate congestion on the existing roadway network for the 10th fastest growing are in the U.S.

 

Location

  • North Carolina, USA

Project Value

  • $737,231,000

Project Status

  • Phase 1 Completed. Phase 2 Ongoing.

The 10th fastest-growing area since 2020 according to the U.S. Census Bureau, the North Carolina Triangle area suburbs needs transportation infrastructure that can keep up with this rapid growth. As development grew south and east of the state capital, commuter trips became longer. With the completion of the Triangle Expressway (NC 540), there will be a new, faster and safer option for travelers that helps alleviate congestion on the existing roadway network.

Coming Full Circle

The Complete 540 project represents a significant milestone in the history of highway infrastructure development by the North Carolina Department of Transportation (NCDOT)/North Carolina Turnpike Authority (NCTA). The project has been executed in two phases, with WSP playing a crucial role in both phases.

During Phase I, WSP served as the lead designer under a design-build delivery contract. This phase encompassed an 8.6-mile segment of the project, which served as a vital link connecting various segments, ultimately forming a 17.8-mile roadway between N.C. 55 in Apex and I-40 near the Johnston County line.

In Phase II of the project, which is nearing construction, WSP's role evolved to providing construction engineering and inspection services. This phase extends the project for another 10 miles, starting from I-40 and culminating at U.S. 64/U.S. 264 Bypass in Knightdale.

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Completed bridge from Phase 1 of the project where WSP construction will begin for Phase 2.

No Matter the Role, It’s All About Solutions

WSP played a critical role in managing Phase I of the construction schedule by implementing innovative solutions like jack and bore techniques and trenchless pipe installation. By designing a bridge over the Norfolk Southern Railroad and utilizing a trenchless 36-inch welded steel pipe, WSP was able to navigate around existing obstacles like the 36-inch corrugated metal pipe and subsurface utilities while ensuring the future track's integrity.

This kind of foresight and problem-solving is crucial in infrastructure projects to minimize disruptions and ensure long-term viability.

For Phase II of the project, WSP’s resident engineer served as a subject matter expert during the procurement phase of the design-build selection and assisted NCTA in project claims avoidance and constructability reviews. WSP is providing critical path method schedule reviews, and in collaboration with our project controls and technology team is streamlining retrieval of relevant and real-time data for NCTA and its stakeholders. WSP has also worked closely with NCTA to provide innovative approaches to environmental compliance on the project. 

Phase 1 Design

  • Project management support
  • All Electronic Tolling (AET) design
  • Permitting and construction drawings for 21 bridges
  • New five-leg turbine interchange

Phase 2 Construction Engineering and Inspection Services

  • Construction Contract Administration and Inspection
  • Construction Materials Sampling and Testing
  • Documentation of Pay Quantities
  • Claims Avoidance
  • CPM Scheduling
Bridges (Phase 1)
22
Lanes of Tolled Highway (Phase 1)
6
Miles (Phase 1)
8.6
Bridges (Phase 2)
29
Lanes of Tolled Highway (Phase 2)
6
Miles (Phase 2)
10.2

Other challenges that we have overcome