# US-74 SHELBY BYPASS — NC-226 TO NC-150

- **Sector:** Transportation
- **Client:** NCDOT
- **Location:** Shelby, NC
- **State:** North Carolina
- **Status:** complete

## By the Numbers

- 5.85M CY Excavation
- 27 Bridges
- 63,000 LF Storm Drainage
- 49,600 LF Wet Utilities
- 510,000 Tons Aggregate Base
- 5300 CY Structural Concrete
- 298,000 SF Concrete Deck Slab
- 43,300 LF Driven Foundation Pile
- 1.2M LB Reinforcing Steel
- 52,000 SF MSE Wall

## Challenge

Construct 12 miles of new interstate with six full interchanges and over eight miles of state and local routes through aggressive North Carolina terrain. The corridor required 27 new bridges up to 560’ long, including three over rivers and two over railroads. Challenging earthwork demanded excavation in materials varying from light silts to mass rock.

## Solution

E.S. Wagner utilized temporary bents for several of the longer steel girder bridges, built four temporary bridges, and effectively managed soils so the best excavated materials could be most effectively used. By delaying earthwork and prioritizing bridge construction as access through the project, the team was able to accomplish off- road hauls approaching 4.5 miles to achieve an earthwork balance that minimized the need for borrow or waste.

## Project Scope

As prime contractor for the first three segments of the US 74 Shelby Bypass, E.S. Wagner helped deliver a major NCDOT corridor project that spanned more than 12 years and endured significant challenges, including utility relocation delays, record rainfall events, and pandemic-related labor and supply disruptions. Through close coordination with NCDOT and innovative construction planning, ESW maintained progress despite factors beyond either party’s control. Key innovations included four temporary bridges, one of which carried live traffic, allowing bridge construction and mass earthmoving operations to proceed safely and efficiently. The project involved nearly 6 million CY of excavation across highly variable geology, including blasted rock cuts and fills up to 60 feet tall. ESW completed 27 bridges supported by nearly 44,000 LF of driven piles and incorporating 5,300 CY of structural concrete, 1.2 million pounds of reinforcing steel, and 52,000 SF of MSE wall. The work also included more than 110,000 LF of underground piping, underscoring the scale and complexity of the bypass program.