Most people don't know where they were on Sept. 27, 2024. Why would they? It's another random day. However, if you ask people in Yancy County, N.C., about the day, many will tell you vivid details about it. That September day was when Hurricane Helene hit. The county, in Western North Carolina in the Blue Ridge Mountains, was devastated. The North Carolina Department of Transportation (NCDOT) and general contractor Archer Western are in the middle of the NC 197 South project, which is one of many projects rebuilding the area's infrastructure.
We Can Rebuild It
NCDOT made a promise to residents of Yancy and neighboring Mitchell counties:
"The intent of these projects is to repair and rebuild roadways and bridges to match pre-Helene conditions and meet current design standards. NCDOT will repair the roadways and bridges in the project limits on the same alignment as pre-storm conditions as closely as possible. Where feasible, NCDOT and its contractors will incorporate resiliency measures to ensure the repairs can withstand future flood events."
The NC 197 South Project consists of rebuilding three bridges and additional permanent roadway repairs. Prior to Hurricane Helene, the bridges were not slated for replacement or repair by NCDOT. There was no need. However, the three bridges, which are a couple of miles apart, were completely destroyed. The storm tore them off the foundations, and the bridges washed down the river.
Note that each bridge was a cored-slab structure supported by a cast-in-place concrete foundation. Two of the bridges span the Cane River, and one is over Cattail Creek. The two over the Cane River are approximately 180 ft. and two spans, while the one over Cattail Creek was around 170 ft. and one span. Each was a two-lane bridge with an ADT of less than 1,000.
"The bridges are going to be replaced in-kind to today's design standards," Colby Justice, NCDOT resident engineer, told Construction Equipment Guide.
In addition to constructing the bridges, the team is performing standard roadwork to tie into the bridges and the embankment slope protection.
The NCDOT hydraulics unit analyzed the river systems in the area and around the region to determine which bridges needed to be made more resilient. The two bridges on the Cane River fit the category. So, the team is installing grounded riprap to improve resilience. The bond between smaller pieces of rip-rap will create a larger object, less likely to be moved by a flood.
NCDOT photo
On-the-ground work on this project began in Summer 2025.
Taking Action
On-the-ground work on this project began in Summer 2025. However, Justice and his team have been on the ground since the initial aftermath and haven't left.
"We oversaw quite a bit of the temporary work, including reconstruction of the roadways," Justice said.
At one point, more than 100 contractors were working simultaneously in Yancey County. There were 500-1,000 trucks, plus the railroad, hauling debris daily.
"NC 197 is the way to access the community and there was 15-20 feet of material debris on the roads," Justice said. "There were damages everywhere and our first steps were survival and reconnecting the community."
It wasn't just broken roads and washed-out bridges that isolated the communities. With cell phone towers destroyed, many residents had no way to communicate with the outside world.
The scene was overwhelming for those charged with cleaning up. Justice cites the famous proverb, "How do you eat an elephant? One bite at a time." He added, "we've installed temporary bridges, repaved roads and reconnected roadways."
One thing that has helped Justice move forward is the appreciation the public has shown for the work he and the team have done.
"Folks pull up and bring us supper to thank us as they saw we're working around the clock. They're very appreciative and understanding."
Quickly Moving Forward
After a storm, one of the main objectives of construction is to get it done as soon as possible.
To quickly advance the project in Yancey County, NCDOT is delivering it through progressive design-build (PDB). It's the first time this method has been employed in the state.
Justice appreciates the benefits of PDB.
"It allows projects to quickly get to the construction phase and allows for flexibility as teams begin construction before design is completed."
To make the PDB project successful, teams need to communicate thoroughly.
"The open book process with the design team is a challenge as is the estimating component," Justice said. "In addition to weekly task meetings, there was more communication, especially up front during preconstruction."
The team also tried to accelerate the process in the early days after the storm to reestablish some sense of routine for residents. The storm impacted approximately 800 bridges throughout western North Carolina. Restoring and/or replacing all the bridges will require an enormous investment of time and money.
NCDOT, including engineers in Yancy County, turned to an unusual method to restore bridges — railcar bridges.
Innovative Bridge Company, with a shop in the North Carolina foothills, has been turning old railroad cars into temporary bridges. Prior to the storm, the railcar bridges had been used privately. NCDOT installed more than 40 to provide access to the mountain counties after the storm.
According to the Raleigh Observer, "they're sturdy enough to handle any traffic for the months or years it will take to build a permanent replacement."
There are, however, some size and weight restrictions. The rail car bridges can be installed quickly and are reasonably priced.
"We had to do something quickly to get access to the communities that were cut off," Justice said.
When the permanent bridges are installed, NCDOT plans to store the temporary bridges around the state, in case they need to be reused in the future.
NCDOT photo
The NC 197 South Project consists of rebuilding three bridges and additional permanent roadway repairs.
Completion
The $21.1 million project is scheduled to be completed in Spring 2027. It's on budget and on schedule. Justice credits the PDB process and the alignment between the state and Archer Western.
Another key is that everyone is aware of the stakes in the project.
"Unlike most transportation projects, there's lots of emotion tied to this project," David Uchiyama, NCDOT communications officer, told Construction Equipment Guide. "People have personal investment in this project. Whether it's on their property or beyond, seeing something brand new is emotional; it brings relief and tears of happiness. It helps ease the wounds that are still healing."
Justice added that he believes completing the project will give people a sense of normalcy and help them return to their lives.
"When we're finally done and they don't see disarray and construction equipment everywhere, they can get back to their lives and rebuilding their property."
