MoDOT is tackling congestion on I-55 near St. Louis, adding lanes and bridges at a cost of $246 million. KCI Construction is spearheading the project, set for completion in December 2026, utilizing innovative technology like drones and Total Station Control for efficient progress.
Photo courtesy of MoDOT
MoDOT has scheduled work over 12 mi. between Route M to Route CC, in the vicinity of Crystal City where Route 61 crosses I-55.
Interstate 55 is the backbone of interstate travel in the Midwest. It roughly parallels the Mississippi River and connects New Orleans, Memphis and St. Louis before heading across the Illinois farmlands terminating in Chicago. In Jefferson County, south of St. Louis, this freeway becomes congested as it works with U.S. 67 in carrying commuters into the city.
The Missouri Department of Transportation (MoDOT) is leading a project to decrease the bottlenecks where these busy highways intersect. Project planners have determined that the work on this $246 million project will decrease congestion and increase safety for motorists and freight haulers.
MoDOT has scheduled work over 12 mi. between Route M to Route CC, in the vicinity of Crystal City where Route 61 crosses I-55. At this point some 50,000 cars travel north with another 35,000 travel south on U.S. 67 toward recreational areas in southern Missouri and toward rural areas that depend on this important highway for transportation.
Photo courtesy of MoDOT
"We have determined that adding a third lane in both directions will enhance safety in that area," said Justin Wolf, project director of I-55 improvements. "We have a wide median in that area, so the contractor has room to add a lane on the inside both north and southbound. In addition, we will be adding a full-width shoulder. This additional space allows us to more easily resolve minor fender benders and enable traffic flow to resume quickly."
MoDOT plans special treatment for the troublesome intersection of U.S. 67 and I-55.
"Right now, there is an at-grade signal, which slows the traffic flow. The contractor will lower U.S. 67 then build a bridge to carry I-55 over that spot, eliminating the need for a signal," said Wolf.
The project will require excavation of some 500,000 cu. yds. of soil and will use 150,000 cu. yds. of concrete. Workers are relocating utilities, with the project slated to be completed in December 2026.
KCI Construction is doing a design-build for the job and is the general contractor. The company is supervising all facets of the construction, while working closely with MoDOT. In addition to building the new lanes of concrete freeway, the company will be milling some asphalt lanes and repaving those with new asphalt. About 40,000 tons of asphalt will be required for this task.
KCI will work on a total of 27 bridges with 14 of the bridges being complete rebuilds; one new bridge at CC; four superstructure replacements; and eight bridge rehabilitations. Many of the bridges have passed their service life with new ones needing to be built taller to accommodate taller loads common in today's traffic.
"We have a variety of types of bridges that we are handling for this project," said Brian Mulhall, project director of KCI.
The work will include:
- Precast girder bridges: These bridges have concrete girders that are cast off site and hauled in and set with cranes. All the completely rebuilt bridges and the new bridge at the 67/CC interchange will be precast.
- Steel girder bridges: In this project, bridges that require longer steel spans have an advantage over precast. The superstructure replacement bridges over Joachim Creek and the BNSF Railroad will utilize steel girders.
- Bridge rehabilitations will be used to extend the service life to several structures. These rehabilitations will involve updating the wearing surfaces of the bridge with epoxy overlays or latex modified concrete overlays.
The quality of the subgrade is an important issue in bridge building. Jefferson County is hilly and rocky which has created some challenges.
"We have done geotechnical borings to provide us information we need," said Mulhall. "The depth of bedrock varies throughout the corridor so some borings may be only 20 feet deep while in other areas we may bore 100 feet deep. This information helps with creating effective design and ordering materials."
Photo courtesy of MoDOT
Much of the rock that has been excavated is being reused in other parts of the project for bridge support, erosion control and subgrade for the new pavement lanes.
"We have been using drones for surveying and progress tracking on the project," said Mulhall. "This process has provided timely information that is accurate and helpful in many aspects of the job."
Other technology that KCI is using has included Total Station Control for earthmoving and paving. This system has enabled the work teams to handle material more accurately and efficiently in all phases of the construction job.
The project has required many traditional pieces of equipment including excavators, bulldozers, articulated trucks, material transfer vehicles, pavers and rollers.
"KCI is honored to be a part of the team for this project," said Brent Krueger, vice president of KCI. "Our organization and our partners are thankful for the opportunity to serve MoDOT and the community in this important project for the region. We look forward to delivering on our common goals and commitments." CEG
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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