Flatiron, in collaboration with joint-venture partner Fred Smith Company and lead designer ICE of the Carolinas, has been awarded a $449.9 million contract for the design and construction of a six-lane divided highway in North Carolina.
The contract is part of the Complete 540 Project under development by NCDOT, and it extends the Triangle Expressway from Rock Quarry Road in Raleigh to US 64/I-87, adding 6.6 miles of new highway and three interchanges. It further builds on Flatiron’s ongoing NC-540 Raleigh Outer Loop projects, advancing the completion of the Triangle Expressway.
Complete 540 Project and the Triangle Expressway Southeast Extension
The Complete 540 project aims to extend the Triangle Expressway from the N.C. 55 Bypass in Apex to Interstate 87/U.S. 64/U.S. 264 in Knightdale, completing the outer 540 loop around the greater Raleigh area (see map below).
By connecting various towns and cities, including Apex, Cary, Clayton, Fuquay-Varina, Garner, Holly Springs, and Raleigh, the project is anticipated to alleviate traffic on local roadways such as I-440, I-40, I-87, N.C. 42, N.C. 55, and Ten Ten Road.
The Complete 540 project unfolds in two phases. In Phase 1, spanning approximately 18 miles from N.C. 55 to I-40/U.S. 70 (future I-42), the Triangle Expressway extension is divided into three sections according to the 2024-2033 State Transportation Improvement Program:
- Triangle Expressway extension from N.C. 55 Bypass to east of Pierce Olive Road (R-2721A)
- Triangle Expressway extension from east of Pierce Olive Road to U.S. 401 (R-2721B)
- Triangle Expressway extension from U.S. 401 to I-40/U.S. 70 (future I-42) (R-2828)
Phase 2 continues the extension, adding 10 miles from I-40 to the existing I-540/I-87/U.S. 64/U.S. 264 interchange in Knightdale, crucially completing the 540 loop. This phase is divided into two sections as per the 2024-2033 State Transportation Improvement Program:
- Triangle Expressway extension from I-40/U.S. 70 (future I-42) to south of Rock Quarry Road (R-2829A)
- Triangle Expressway extension from south of Rock Quarry Road to I-540/I-87/U.S. 64/U.S. 264 (R-2829B) – This Contract
Related Project and News – Flatiron Projects
Triangle Expressway Southeast Extension - Scope of Works and Contracting Approach
NCDOT has employed a design-build contracting framework to procure the Triangle Expressway Southeast Extension project. In this approach, the contractor (Flatiron-Fred Smith JV) assumes responsibility and risks for both the design and construction phases, facilitating a substantial risk transfer from the owner (NCDOT) to the contractor.
Suggested Reading: Design and Build (D&B) Contracts – How do they Work?
The scope of works encompasses the following crucial elements:
- New interchanges at Rock Quarry Road, Auburn Knightdale Road, and Poole Road.
- Construction of 19 new bridges, including approximately 1,600 feet of dual bridges over the Neuse River.
- Rehabilitation and widening of the existing I-540 bridge over I-87.
- Realignment of the existing Neuse River Trail.
The Flatiron-Fred Smith Company joint-venture team is actively collaborating with the North Carolina Turnpike Authority on design and preconstruction planning for the $449.9 million Triangle Expressway Southeast Extension, marking Flatiron’s third contract on the Triangle Expressway project.
The team’s innovative design approach introduces an “over-under” direct-connector ramp for southbound I-87 to westbound NC-540 traffic (shown above), aiming to reduce costs, accelerate schedules, and minimize traffic impacts during construction. Additionally, the team has optimized the design to reduce planned earthwork by 1.3 million cubic yards.
Triangle Expressway Southeast Extension Contract – Flatiron Leadership Comments
Jim Schneiderman, Flatiron Senior Vice President for the Mid-Atlantic Division, expressed enthusiasm about constructing another section of the Triangle Expressway.
He highlighted the project’s significance in fostering continued growth and greater opportunities in the rapidly expanding urban area, making day-to-day travel safer and more efficient.
Flatiron is concurrently constructing two other NC 540 Raleigh Outer Loop segments in collaboration with Branch Civil.
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