Thursday, October 1, 2026
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Pigeon River Gorge, NC (WNN)— A nice leisurely drive through scenic mountains can be enjoyable, unless it is a major artery connecting Tennessee and North Carolina, and traffic is at a standstill. Unfortunately, a stretch of I-40 is notorious for temporary impediments due to rockslides and flooding.
A portion of I-40 being reconstructed.
June 27th, 2025. Photo from: NCDOT
This area of the Pigeon River Gorge sustained heavy damage last September from Hurricane Helene. A seven-mile stretch reopened with one lane in March 2025. It would later be closed again due to flood damage from heavy rain in June. This section has been open since June 27, 2025, albeit with one lane. The roadway follows the natural flow of the river, creating breathtaking views, but traffic nightmares when it is reduced to just one lane. Crews have been working extended hours since shortly after the flood damage from Hurricane Helene.
Although amazing progress has already been made, the process has been painstakingly slow. Safety, preserving natural wetlands, wildlife, and logistics have slowed the efforts. A major stumbling block was the need for rock to build a retaining wall and stabilize the road. This is a huge problem, as Tennessee's closest quarry is 20 miles away.
The need for extra construction traffic moving rock between the two states created safety issues and worsened the already slowed traffic flow. A solution was needed.
Plenty of rock was located within a mile of the construction site; however, there was a slight problem. The rock was in the middle of the Pisgah National Forest. A designation that protected the forest, wildlife, hiking trails, and wetlands from being disturbed, developed, or mined. The forest covers an area of approximately 500,000 acres.
If construction crews could access that land, rock could be excavated and hauled across the river. There was another problem, the river. The Pigeon River lies between the Pisgah National Forest and I-40. Access to that rock could save time bringing in much-needed material, dramatically reduce the time needed to reconstruct the missing section of road, and lower the cost. First things first. The North Carolina Department of Transportation partnered with the U.S. Forest Service to obtain the necessary permits and approval to access the national forest land for mining.
Pigeon River Gorge near the TN state line
May 20th, 2025. Photo from: NCDOT
The USFS gave a special use permit to NCDOT to test potential sites in which to obtain rock. The next step was a temporary land transfer to the Federal Highway Administration; in turn, they granted NCDOT a temporary easement to remove rock from the forest. Other agencies involved include the U.S. Army Corps of Engineers, U.S. Fish and Wildlife Service, N.C. Division of Water Resources, and N.C. Wildlife Resources Commission.
A 33-acre site was selected for its proximity and viability. It will also produce the lowest impact on the protected forest. An adjacent 11.5-acre site has also been obtained to store material that is not suitable for the project. After all the reconstruction is complete, this material will be vital in restoring the forest.
Three million cubic yards will need to be removed and transported to the work site. Due to the river's location, a causeway was recently completed that runs below the interstate along the river. This will allow construction traffic to avoid impeding I-40 traffic. Engineers will also be able to inspect roadway supports close-up and determine where to best build retaining walls.
A temporary bridge is being built across the river to transport the rock from the forest to the interstate while facilitating the mining operation. The project's contractor, Ames Construction, will construct the retaining wall with rock mined from the national forest. The current plan is cheaper, safer, and allows for the protection of the forest and wildlife.
What are the long-term plans? What about the federally protected forest? Current estimations place completion of the road project in early 2028 for $1.3 billion. NCDOT installed a series of monitors that gather real-time readings on potential earth movements that can determine the possibility of future road damage and rockslides.
Long-term plans are being made to restore and improve the areas being mined. The leftover materials of rock and soil will be returned to the land to restore any temporary damage. Aquatic life and wildlife habitats will improve conditions and be better protected from natural disasters. The goal is to ultimately not only restore the land but also improve it as well. Safeguards and protection for generations to come are in the discussion stages.
Smoky Mountains, East Tennessee
July 27th, 2013. By: Roger Sigmon (WNN)
The Pisgah National Forest is home to wildlife such as black bears and bobcats. Every precaution is being taken to provide a continued safe habitat for these animals and the many others that call this area home. In the meantime, drivers need to exercise caution and patience in the 12-mile area crossing between North Carolina and Tennessee. Keep in mind that this is a massive multi-year project that will require time and patience to complete.
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