A major construction project at Exit 74 on I-95 in East Lyme, Connecticut involves raising the interstate 14 ft. using retaining walls and earthwork to improve safety, sightlines, and congestion. The $150 million project faced challenges but aims to be completed by 2027 while prioritizing safety and environmental impact.
CTDOT District 2 photo
The project worked with environmental specialists to reestablish plantings and improve nearby wetlands, floodplains and streambeds.
Interstate 95 runs through the southern section of Connecticut, often within sight of Long Island Sound. This important freeway connects New York City and its vital commerce with Boston in the north and the rest of New England.
In East Lyme, the Connecticut Department of Transportation (CTDOT) has undertaken a major construction project at Exit 74 where the interstate travels over Route 161. The project will improve sightlines, make the road safer for travelers and ease congestion.
CTDOT plans to have the project completed by 2027 at the cost of nearly $150 million. By the completion of the project, I-95 northbound and southbound will have a new look. The northbound and southbound lanes will be raised approximately 14 ft. from their original position on the west side of Route 161 and cut approximately 10 ft. on the east side.
Contractors are achieving these changes through the construction of temporary earth retaining systems (TERS). Andrew M. Millovitsch, project engineer, is overseeing the project for CTDOT. To create the 16 retaining walls necessary for the project, workers needed to pulverize a massive ledge with explosives. Each blast required a full closure of I-95. Manafort Brothers was the general contractor for the project and worked closely with additional contractors on the job.
The blasts enabled workers to remove 60,000 cu. yds. of material to make way for a new retaining wall adjacent to I-95 northbound. The construction team experienced a major setback when a soil nail wall failed to hold, costing the team two months. The team accelerated the work for five months to bring the project back on schedule. The project is now 50 percent complete.
The contractor is building extended lanes for both acceleration and deceleration for the interchange ramps. The team also is constructing a 6-ft. raised median and 12-ft. shoulders for both north and southbound traffic.
"We have had some existing soil conditions that have proved challenging," said Millovitsch. "The newly constructed roadway will provide safe areas in the median to handle breakdowns. Drivers will have better sightlines to view the traffic they are driving in and have flatter slopes to improve stopping distances. Also, the new overpass will allow for safer clearance for motorists on Route 161."
As the 2025 construction season opens, workers will shift traffic onto the recently constructed travel lanes and over Route 161. An additional TERS will be constructed closer to the southbound traffic.
"At that time, the northbound traffic will be brought to final grade and the next third of the bridge construction can take place between the north and southbound lanes," said Millovitsch.
Having a Blast
Blasting proved exciting not only for the construction team and onlookers but also had many practical benefits. A major obstacle was removed, and the remains from the blast were crushed and used for subbase for the road and for fill as part of the embankments. Both steel and asphalt were recycled as well. The project worked with environmental specialists to reestablish plantings and improve nearby wetlands, floodplains and streambeds.
The team plans to use approximately 80,000 tons of asphalt for the roads and 10,000 cu. yds. of concrete for precast items including drainage structures and retaining walls, as well as cast-in-place elements for the new Bridge No. 00250.
The construction team used a traditional fleet of equipment for the job including excavators, front loaders, cranes, paving machines and rollers. Construction teams are increasingly using technology to complete the jobs with greater precision and speed. The technology used for this job included 3D modeling, drone-assisted GPS survey equipment, geo-located software and "open road designer" to assist with placement of proper quantities of material.
CTDOT and contractors were careful to maintain safety both for workers and motorists. Because the work was done in stages, safety specialists were able to delineate work zones and keep the construction activity behind temporary barriers. The work team also used speed camera vehicles to slow down traffic and keep the work zone protected.
The I-95 East Lyme project has been both satisfying and challenging for Millovitsch and his team.
"The vertical realignment of I-95 was a complex challenge," he said. "This work has allowed us to improve the safety of a historically substandard piece of road. It has also been an area that is accident prone. We hope that will be improved as well." CEG
(All photos courtesy of CTDOT District 2.)
Chuck MacDonald
Chuck MacDonald is an editor, blogger and freelance feature writer whose writing adventures have taken him to 48 states and 10 countries. He has been the editor for magazines on pavement construction, chemicals, insurance and missions. Chuck enjoys bicycling, kayaking and reading. He graduated from the University of Missouri with a degree in journalism. Chuck lives in Annapolis, Md. with his wife Kristen. They have seven grandchildren.
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