Gold Rock I-95 Interchange
Despite extensive night work, a convoluted ramp system, heavy traffic, and even a nearby tornado, Barnhill Contracting Company pressed forward with the I-95 Interchange project at Gold Rock in Battleboro, NC. Construction began in August 2021, just one month after the site became available. The project involved removing four deteriorated bridges and replacing three of them with help from Sanford Contractors. One bridge was rebuilt with a complex ramp system that was replaced by two roundabouts and ramps at the NC 4 Interchange, designed to meet future widening standards. Two more bridges were rebuilt at NC 33 and Watson Seed Farm Road, while the fourth was eliminated and rerouted through roundabouts. These upgrades improved travel ease and safety across a six-mile stretch, using 22,000 tons of asphalt and 3,000 linear feet of storm drain.
The completed project streamlined traffic into the new CSX hub and improved flow for Wake Stone Quarry’s dump trucks. Wake Stone also partnered with Barnhill, supplying 200,000 cubic yards of borrow material. Safety was a top priority throughout the three-year build, with monthly accident-free lunches and a strong safety culture. Barnhill’s collaboration with NCDOT helped resolve issues quickly, including a key discovery that existing shoulders met design standards—saving time and money. Wick drains were installed before building the NC 4 bridge to manage groundwater, a rare move for the region. Seven ramps were shut down and reopened on schedule, thanks to tight coordination and round-the-clock work.
Another standout feature of the project was Barnhill’s use of full concrete paving in the roundabouts and between bridges—an uncommon approach in North Carolina. Certified Concrete provided ready-mix material, and the team worked closely with NCDOT engineers to finalize specifications and approvals. This innovation added complexity but resulted in durable, long-lasting infrastructure. Crews also had to build a temporary wire wall near a hotel to preserve parking during detours and unexpectedly rebuild Archibell Road when its condition deteriorated under redirected traffic. These extra efforts showcased the team’s adaptability and commitment to keeping the project on track.
