An ongoing effort that will resculpt the landscape and provide a critical new route continues in Lawrence County, Ohio. Work began last year on the $128.5 million second phase of the Chesapeake Bypass project.
“The project will move about five million cubic yards of rock and earth to create space for the new highway, connecting the previously constructed portions to complete the relocation of State Route 7 away from the Ohio Riverbanks and around the villages of Chesapeake and Proctorville, Ohio,” Ohio Department of Transportation (ODOT) project manager Tom Barnitz told Construction Equipment Guide. “The initial construction work to relocate this highway began in 1979.”
Barnitz said building a highway through the foothills of the Appalachian Mountains is a colossal undertaking.
“Years of effort by various teams at ODOT are necessary before the first shovel of dirt can be excavated. Behind-the-scenes work to plan the location of the new route, perform environmental studies, design the highway and then purchase the right-of-way is just the beginning of a 4- to 5-year-long effort to construct the highway.
“All major highways in Ohio, as well as other neighboring states that have to contend with the Appalachian Mountains, face similar monumental tasks in order to provide access into and out of this region that is rich in natural resources. These highways provide access for businesses to relocate into these areas, driving economic development, and for people who live there to more easily access other areas in the region.”
Mass earthwork is continuing, and construction has started on six of the nine bridges. Due to the size of this effort, there are concerns with keeping it on schedule and within budget. Kokosing serves as contractor on the project, which calls for the excavation of roughly 5 million cu. yds. of dirt. This amount is the equivalent of 100,000 truckloads.
“Ohio is fortunate to have contractors in the state and located in surrounding states who have experience with projects of this earthwork size,” said Barnitz, who explained that since the project is primarily a greenfield project, little impact on heavy traffic routes is anticipated. There are, however, some temporary closures needed on some smaller state, county and township roads.
According to Barnitz, completion is expected in late fall 2028, with some work possibly stretching to 2029 due to unknown delays.
“ODOT has been working for years to complete the project and joins many in the community and other stakeholders anticipating opening the road to traffic in a few short years. The new highway will serve the residents and regional traffic for decades to come, and make a positive, lasting impact on this growing portion of southern Ohio.”
ODOT area engineer Chris Capper told Construction Equipment Guide that the biggest challenges for crews at this time is constructing the bridge abutment earthen embankments prior to winter shutdown. This work is necessary in order to begin the settlement period of 180 days during the winter weather period of slower production.
Capper also said on the eastern end of the project a large hill must be excavated to get the material needed for embankment work.
“Blasting continues daily. Crews are utilizing nine 100-ton rock trucks to haul material, which are being loaded by a Komatsu 2000 excavator that has a 16-cubic-yard bucket weighing approximately 450,000 pounds.”
Approximately 75 percent of the total material has been excavated. This still leaves approximately 30 ft. that the hillside must come down to reach finished grade.
Bridge pier foundations and concrete piers for the three bridges crossing Little Paddy Creek have already been completed. Beams for the center span should be set this fall. Multiple culverts have been installed, with the longest being 921 ft. long. It will be 130 ft. deep once the embankment is completed.
Capper noted the focus in 2027 will be completing the structures.
“Currently, work has started on six of the 10 structures. Reinforced earthen embankment operations will continue through the spring.”
Major equipment on site includes nine Komatsu 785 rock trucks (100 ton); seven Cat 745 articulated trucks; one Komatsu 2000 excavator; two Komatsu 1250 excavators; multiple dozers; smaller excavators; soil compactors; and rollers.
Materials include concrete for the structures, steel reinforcement, steel straps for the MSE wall and stone to prepare the roadbed for paving CR 69 from CR 118 to SR 243 later this fall.
“The weather impacts everything we do,” Capper added. “This summer was generally conducive to earthwork. The project has had more rain than 2025, but it hasn't hindered production. Moderate amounts of rain can actually help on the project by reducing dust and aiding in compaction. At this time, everything remains on schedule.”
Although much work remains, Capper said it's an honor to be part of the construction team, adding,
“The biggest reward is working on a project that will be used by many future generations.”
