Photo courtesy of TDOT
Completing the Newport Bypass requires significant excavation, construction of new bridges, box culvert construction, box culvert extensions, as well as traffic control and detours.
Currently under construction by the Tennessee Department of Transportation (TDOT), a $67 million project will provide drivers with a safe, more efficient route for SR 35 to pass through Newport, Tenn., avoiding downtown traffic. Completing the Newport Bypass requires significant excavation, construction of new bridges, box culvert construction, box culvert extensions, as well as traffic control and detours.
Photo courtesy of TDOT
"Newport Bypass will be 4.75 miles of entirely new alignment," said TDOT spokesperson Mark Nagi. "This project consists of grading, drainage, construction of four concrete Bulb-Tee beam bridges, signals and paving on SR 35 from SR 9 to Saint Tide Hollow Road."
According to Nagi, two of the structures are located along the five-lane section of improvement. The first bridge crosses Stinking Creek, while the second crosses Lisega Boulevard, Norfolk Southern Railroad and the Pigeon River. The other two bridges are located along the interim two-lane section, one crossing the French Broad River Flood Channel and the other crossing the French Broad River.
Work on the Cocke County project began in 2022 and should be completed by late fall 2025. Charles Blalock & Sons Inc. serves as the prime contractor and has employed more than two dozen subcontractors for tasks ranging from landscaping to bridge building.
Nagi said keeping everyone out of harm's way is the top priority, as workers construct more than 4 mi. of entirely new alignment.
"Given the number of large cuts and fills on this project, extreme caution has been taken to ensure employees operate safely."
As for the overall scope of work, said Nagi, "The scale of the project is impressive. There are 1.343 million cu. yds. of road and drainage excavation, and two bridges over rivers with highly variable flow. Highly saturated silty soils through many low lying areas have proven to be challenging.
"Grading and drainage on this project involve large equipment, such as trackhoes, graders, bulldozers, scrapers, rollers and dump trucks working sun-up to sun-down to cut these hills down and build embanked earthen fills. Also, given the abundance of shale and rock on this project, the contractor has implemented drilling and blasting."
Nagi noted that constructing four concrete Bulb-Tee bridges is a long process.
"It involves building the abutments, foundation, substructure [footing, columns and caps], setting the Bulb Tee beams, and pouring the deck and parapet walls. Each of these processes takes considerable time and work, given the size of these bridges. Large cranes are absolutely needed to build these large structures. Working over/in water requires cofferdams and dewatering plans."
Setting beams and securing railroad protective services for work over the railroad at Bridge 2 is another concern for crews.
"Working with the railroad requires extensive coordination. While we have not begun to work near the railroad's right-of-way on the Newport Bypass project, the contractor intends to start in the coming months. While we are working near the railroad, a flagman will coordinate with the railroad to ensure that we do not disrupt the track schedules and that we work in a safe manner."
Regarding bridge work, Nagi said, "Bridge 1, over a small stream named Stinking Creek, is still under construction. The contractor is wrapping up building the substructure. Bridge 2, which crosses over the railroad and the Pigeon River, also is having its substructure built. Bridges 3 and 4 have been all but completed. They are drivable, but are missing a few small work items, such as painting and grooving."
Photo courtesy of TDOT
Paving on SR 35 from SR 9 to St. Tide Hollow Road has yet to be carried out.
"After earthwork is complete, the contractor will place base stone and compact it. The contractor will then pave. This requires an asphalt paver, shuttle buggy and steel wheel, vibratory and pneumatic rollers. There will typically be four layers of asphalt on this project, which total 9.25 inches."
The weather, Nagi explained, has been an issue for workers.
"It's been challenging at times, with substantial rainfall, but the contractors have been adamant about going above and beyond with EPSC measures. We had a few issues early on with larger storms, but we have learned from them, moving forward."
Despite the ongoing concerns, Nagi said it's rewarding to work on a project that will serve motorists well into the future.
"Knowing the impact this bypass will have on the Newport community is an encouraging thought, but also knowing the impact it will have on everyone that drives through this area is amazing.
"Recognizing the potential improvement to the lives of the Newport citizens is encouraging, as we see the progression of this project." CEG
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