U.S. 411 runs more than 300 mi. and extends from Leeds, Ala., to Newport, Tenn. The Tennessee Department of Transportation (TDOT) is nearing the end of a widening project of U.S. 411 in Jefferson and Sevier counties, which are in the center of the state. The current project is the third phase of construction on the highway. The three phases cover 9.3 mi. of U.S. 411. The first phase began in August 2012.

Tourist Area

TDOT photo

The section of U.S. 411 the team is working on is near Pigeon Forge. The town, surrounded by the Great Smoky Mountains, is home to Dollywood and a variety of activities. The "… year-round family-friendly vacation destination…" draws tourists from the state and beyond.

The ADT in 2023 was 8,020, and it's projected to reach 13,630 in 2043.

Before the widening and realignment of U.S. 411, the highway had just two lanes in the project area. Upon completion of the project, the highway will have five lanes — two lanes in each direction, a center turning lane and 12-ft. shoulders (10 ft. paved).

In the third and final phase of the project, the team, which includes general contractor Jones Brothers, is realigning nearly 4 mi. of U.S. 411. This section will have three lanes as it connects to another section of U.S. 411, which is three lanes. The project also includes the construction of five box culverts.

Jones Brothers, headquartered in Mt. Juliet, Tenn., a suburb of Nashville, has been around since 1946. The heavy highway and civil construction firm specializes[s] in the development and construction of complex essential infrastructure projects."

Dirt Moving

Greenfield projects typically require significant dirt moving. That's certainly true for the project at hand.

TDOT photo

"We're going through undeveloped land that includes hills up to eighty feet tall," Jesse Joyner, TDOT team lead told Construction Equipment Guide. The team estimates the project will entail excavating 1.456 million cu. yds. of dirt.

Some sections of the new alignment will be more than 40 ft. above the current alignment. "We're trying to balance the project and use the cut we make," Joyner said. "We bank the cut and use it as we need it."

Joyner added that "We have no good way to move the dirt on the existing infrastructure, as some trucks are too heavy and will damage the road. So, on occasion, the contractor will have to stick with smaller trucks to move the dirt in the project."

Note that the project requires more dirt than what is on site.

The team also has encountered a significant amount of rock, which required blasting to remove it.

The new alignment crosses the existing alignment twice.

"This makes it hard to keep traffic moving," Joyner said. The height differential between the new and existing alignment eases the challenge. To keep traffic moving, the team constructed a few temporary tie roads.

The team is facing another challenge, environmental concerns, due to its proximity to Douglas Lake. The lake is a popular recreation destination for paddlers, anglers and campers. They need to ensure that waste from the site doesn't drain into the lake.

The challenge became clear at the start of the project, when heavy rain fell.

"We have to be on top of erosion control to make sure the runoff is clean," Joyner said.

He pointed to three steps the team has taken to protect the lake — upsize their check damns; install additional temporary silt fences; and get the grass back as soon as possible.

TDOT photo

The environmental issue has been a challenge for the contractor.

"It's a balancing act for the contractor," Joyner said. "They want to move the project forward briskly but before doing so, they have to make sure what's behind them is stabilized."

The state's environmental department does biweekly inspections and monthly quality assurance checks.

On Budget, On Schedule

The current project has a $64 million budget. The federal government is paying 80 percent of the construction costs while the state is handling the remaining 20 percent.

The project is currently on budget. Joyner attributes that to a good set of plans. A second factor is having an inspection team that understands what the contractor is doing, accurately reports it and raises issues in advance so the team can address them quickly and minimize impact.

TDOT has an outside inspection team, Mattern & Craig, on the project. The Roanoke, Va.-based company "offer[s] comprehensive civil and sanitary engineering services to public, corporate and governmental agencies."

"We've been using outside consultants more often the last few years as we find it beneficial for day-to-day operations and the big picture," Mark Nagi, TDOT Region 1 regional communications officer said to Construction Equipment Guide.

Construction on the project began in late spring 2023 and is scheduled to conclude at the end of October 2026. The project is on schedule.

"The contractor has kept the project moving forward," Joyner said. "Plus, there have been only a few hiccups, and when issues have arisen, we've resolved them quickly."

One issue Joyner noted revolved around the size of the box culverts. The contractor noticed this during a review of the plans before beginning construction. Joyner wrote the change order, and the necessary quantities of concrete and steel were ordered.

Upon completion of the project, drivers along U.S. 411 in Jefferson and Sevier counties will have a more reliable commute. Tourists headed to Pigeon Forge and other destinations will be able to enjoy their vacation spots more quickly. CEG