# US-74 Design-Build

Interchange & Bridge Replacement - C204860

- **Sector:** Transportation
- **Client:** NCDOT
- **Location:** Mooresboro, NC
- **State:** North Carolina
- **Status:** in\_progress

## By the Numbers

- 600k CY Earthwork
- 3.2k CY Structural Concrete
- 650k lbs of Structural Steel
- 3 Demolished Structures
- 4 New Bridge Structures

## Challenge

Rock encountered during interchange ramp excavation required blasting operations, while utility relocation and Right of Way acquisition delays impacted critical path operations. These conditions required ESW to strategically adapt and resequence earthwork operations to maintain progress.

## Solution

ESW implemented a proactive, continuously evolving execution strategy to overcome significant early schedule impacts. Through strategic resequencing, intensive coordination, and ongoing schedule analysis, the team successfully recovered the initial six-month Right of Way Acquisition delay and continues to gain ground on time lost to utility delays at project start-up.

## Project Scope

As prime contractor, E.S. Wagner is delivering the US 74 Design-Build project in Mooresboro, NC, in partnership with Summit Design & Engineering Services. The project includes improvements to 1.63 miles of four-lane US 74 and approximately one mile of new two-lane local roadways, highlighted by a new grade-separated interchange with four new ramps. Construction began in the field in February 2025, with completion anticipated in October 2027. The three-phase project includes four new bridges, demolition of two existing US 74 bridges and an abandoned railroad bridge, two MSE walls, a sound wall, and a box culvert. Major quantities include approximately 380,000 CY of onsite excavation reused as fill, 220,000 CY of imported borrow, 13,580 tons of asphalt pavement, and 140 LF of drilled pile foundations. Utility and drainage work includes storm sewer up to 78 inches in diameter and water main installation up to 8 inches. Complex staging and traffic maintenance are integral to construction, with Phase 2 focused on completing the new interchange and eastbound US 74 alignment under a one-year intermediate completion requirement. Despite initial right-of-way and utility relocation delays, ESW has recovered the six-month right-of-way impact through continuous schedule analysis, strategic resequencing, and adjustments to earthwork operations while navigating rock blasting and utility conflicts.