Southeastern Wake County, N.C., enters a new era of connectivity and opportunity with the success of the Complete 540 project. This transformative initiative, led by the North Carolina Turnpike Authority (NCTA), was crafted to meet the region's growing transportation demands and stimulate economic development, and that is why it is our No. 1 Road project of 2024.
At the forefront of the project was Gannett Fleming, the lead design firm responsible for a critical 4.6-mile segment. Their innovative approach utilized a design-build delivery method, expediting completion while allowing for creative problem-solving.
"Being recognized validates the collaborative efforts of our design-build approach, where we addressed complex challenges through creativity and a commitment to sustainability,” said Jerry Page, a P.E. and preconstruction services manager at Gannett Fleming. “This award is a reflection of the transformative impact our work will have on the community for years to come."
One of the most striking features of the Complete 540 project is its diverging diamond interchange (DDI). This cutting-edge design redefined traditional traffic patterns, allowing vehicles to cross to the opposite side of the road. By reducing conflict points, the DDI significantly enhanced safety and improved traffic flow, a vital consideration given projections that the highway would soon carry 50,000 vehicles daily.
Construction was equally impressive. It featured nine bridges, 11 concrete box culverts and over 2.5 miles of aesthetic brick noise walls.
Innovation was crucial to the project’s success. The team used AutoCAD Civil 3D for operational planning and SiteIQ for tracking earthwork movements via drone. These tools not only facilitated real-time oversight, but also enhanced safety by allowing remote assessments of site conditions.
Despite facing significant hurdles, including the largest utility relocation agreement in North Carolina's history—$50 million involving Colonial Pipeline—the project team remained agile. Early coordination with utilities allowed for successful relocations before major construction began, demonstrating effective planning and execution.
The project also prioritized environmental stewardship. In sensitive areas, a temporary steel trestle was employed, and specialized tolling equipment was installed with minimal ecological disruption. Recognizing potential threats to endangered freshwater species, the team committed $5 million to habitat preservation and restoration efforts, showcasing their dedication to sustainability.
Community outreach also played a vital role in the project’s success. A dedicated project website and hotline provided stakeholders with continuous updates, addressing over 500 inquiries. Public meetings in Raleigh fostered transparency and trust, while “Dear Neighbor” postcards were sent to residents. The postcards informed about construction phases and helped to mitigate disruptions to daily life.
As the project approached its grand opening on Sept. 25, 2024, it stood as a model of innovation and sustainability. The final product enhanced connectivity within the region, raised property values and attracted new development.
"Earning this distinction is a testament to the innovation and dedication of our team,” said Michael Holder vice president of transportation services at Gannett Fleming. “The Complete 540 project challenged us to push the boundaries of design with cutting-edge solutions like the diverging diamond interchange, ensuring the safety and efficiency of Raleigh’s growing transportation network."
The Complete 540 project was more than just a roadway; it was a commitment to the community—a promise that engineering excellence and collaboration could yield safe, efficient and sustainable transportation solutions for generations to come.
As the sun sets over the newly opened highway, it symbolizes a new chapter for Raleigh and its residents, a testament to what can be achieved when vision meets determination.
"This recognition highlights the North Carolina Turnpike Authority’s commitment to delivering projects that improve mobility and foster economic growth,” said J.J. Eden, executive director, NCTA. “The Complete 540 project stands as a vital link in our region's infrastructure, and this award underscores its importance to the future of transportation in North Carolina."
Project: Complete 540 N.C. 55 Bypass to East of Pierce Olive Road
Location: Wake County, N.C.
Owners: North Carolina Turnpike Authority
Designer: Gannett Fleming
Contractor: Flatiron Construction and Branch Civil Joint Venture
Cost: $183,459,000
Length: 4.6 miles
