As Hurricane Helene devastated the Southern Appalachians, it brought a deluge of water that destroyed hundreds of miles of roads, from winding mountain roads all the way to interstate highways.
When the ground beneath Interstate 40 collapsed into the gushing Pigeon River Gorge, traffic through North Carolina came to a halt. The eastbound lanes were hit the hardest, with entire sections washed away. Suddenly, more than 25,000 vehicles through Pisgah National Forest on I-40 had to be rerouted, causing major impacts across the region.
The U.S. Department of Agriculture’s Forest Service quickly began coordinating with North Carolina Department of Transportation to piece back together one of North Carolina’s largest corridors of commerce, Interstate 40.
“Many travelers may not realize they are passing through national forest lands as they cross into North Carolina from Tennessee on I-40,” said Allyson Conner, National Forests in North Carolina Department of Transportation (NCDOT) liaison. “We wanted to assist NCDOT in restoring a lifeline to communities, travelers and commerce. We worked closely with Federal Highways Administration and NCDOT to support the repair process while also protecting the natural and cultural resources of our forest.”
Locally sourced, local success
In March 2025, North Carolina Department of Transportation reopened one lane of traffic in each direction, using the west bound lanes of I-40 at reduced speeds. However, this was only a temporary solution. To reopen the road completely, NCDOT needed more than three million cubic yards of rock and soil to replace and rebuild what Helene had scoured away.
To save money and time, North Carolina Department of Transportation identified a nearby location within Pisgah National Forest that could serve as a source for the rock and soil needed to rebuild I-40. By using local materials from the Pisgah National Forest, it saved taxpayers nearly $100 million and up to three years of construction time.
The National Forests in North Carolina advised NCDOT during the process. Specialists including botanists, hydrologists, archeologists and wildlife biologists shared input on protecting natural and cultural resources as well as recreation and private landowner considerations.
"We greatly appreciate the cooperative mindset the staff of the National Forests in North Carolina brought to every conversation,” said John Jamison, environmental policy manager with North Carolina Department of Transportation. “Their expertise helped us quickly understand our project constraints and responsibly address our potential effects.”
Connecting people, rebuilding better
Together, NCDOT and the National Forests in North Carolina agreed on future improvements that will offset the project’s impacts and benefit the entire forest and surrounding communities. These include land donations, wildlife passages and stream restoration.
“More than 1,000 acres will be added to the National Forests in North Carolina, which is a win for the public and future generations as we strive to improve public access and habitat corridors for wildlife,” said Forest Supervisor James Melonas.
Aquatic organism passages and wildlife crossings will also be installed in key areas of the forest to help animals move more freely and safely. In addition, a frequently flooded low water Pigeon River crossing will be removed and replaced with a higher elevation bridge, helping landowners get in and out during heavy rainfall.
“North Carolina Department of Transportation and National Forests in North Carolina both want to do what’s best for the land and for the people who rely on this highway every day,” said Jennifer Barnhart, district ranger on the Pisgah National Forest. “This is a great example of how collaboration and teamwork can lead to smart solutions.”
In the end, the project wasn’t just about fixing a road. It’s about connecting people, protecting nature and building something better than it was before.
Subscribe to our newsletter to keep up with all Forest Service feature stories!