The Kentucky section of a transformational road project, which will generate a new four-lane river crossing between the state and neighboring Indiana, is nearing completion. The I-69 Ohio River Crossing (ORX) Project will complete the Interstate 69 connection between Evansville, Indiana, and Henderson, Kentucky. A new I-69 bridge across the Ohio River is expected to improve traffic flow, reduce delays and congestion, and enhance driver safety. The connectivity it provides is poised to be a benefit to both cities, both states, and the entire region — supporting safer and more efficient movement of people and goods in the region, along with opening the door to new economic opportunities.

Interstate 69 will be a new, national north-south interstate corridor which, when completed, will be a new route connecting Mexico to Canada.

The I-69 ORX Project is divided into three sections for project delivery, with approach work on both sides of the river planned for completion prior to the start of bridge construction. Section 1 is the approach work in Henderson and is being overseen by the Kentucky Transportation Cabinet (KYTC), the state's department of transportation. Work on Section 1 began in 2022 and is on track for completion in late 2025. This phase includes a 6-mile extension of I-69, as well as interchanges with KY 351, U.S. 41, and U.S. 60.

I-69 ORX Section 2 will be a bi-state project, which includes the new four-lane river crossing. The bridge will ultimately be owned equally by the two states. Construction is currently expected to begin in 2027 and be complete in 2031. The bridge is the final I-69 connection for the two states.

Section 3 of the I-69 ORX Project includes approach roadways and bridges in Indiana. Those roads and bridges will provide the important all-weather construction access to build the future I-69 bridge. Work started in fall 2024 and is expected to be complete in late 2026. The Indiana Department of Transportation is leading the Section 3 construction.

“It’s hard to believe this project is so close to completion,” said Emily Deason, KYTC's I-69 ORX Section 1 Project Manager. “It’s incredible to see the amount of work that has been done and the transformation that has happened in just a few short years. Henderson is the start of completing the I-69 connection with Evansville, and the positive momentum we’re seeing here will lead right into procurement and soon construction of Section 2 of the project, the future I-69 bridge.”

The cost of Section 1 is $158 million, which is fully funded with state and federal dollars. KYTC awarded the design-build contract in 2021 to the team of Ragle, Inc., based in Newburgh, Indiana, and Stantec Consulting Services, Inc., of Lexington, Kentucky.

The improvements in this phase include:

• An over 6-mile extension of I-69.
• Nine new bridges.
• Seven rehabilitated bridges.
• A new U.S. 60 interchange, with three roundabouts that will facilitate moving traffic on and off I-69 and east and west along U.S. 60.
• A new U.S. 41 interchange that, when complete, will be in a long-term interim configuration until after the I-69 bridge is complete. In its final configuration, U.S. 41 will be an exit off I-69.
• Reconstruction of the KY 351 interchange, with three roundabouts.

“The reconstructed KY 351/2nd Street interchange and the new U.S. 60 interchange both include three roundabouts — a roundabout and a dog-bone,” Deason said. “These designs work very well for these interchanges. We were able to remove traffic signals at KY 351. The roundabouts keep traffic moving, safely and efficiently.

“Roundabouts have been proven to greatly improve safety. Statistics from the Federal Highway Administration show roundabouts reduce fatal crashes by 90 percent, injury crashes by 75 percent, and all crashes by 37 percent.”

A “dog-bone,” or double teardrop, roundabout resembles the shape of a dog bone from an aerial view. Dog-bone roundabouts are employed in places where a fast arterial or highway intersects a smaller street. It is a bit like a cloverleaf interchange, but with the additional benefit of slowing and separating traffic converging at the center of the intersecting road.

A major Section 1 milestone was the opening of the reconstructed KY 351/2nd Street interchange. Three new roundabouts were constructed at the interchange while traffic was maintained along the busy corridor. The roundabouts opened in temporary (single-lane) configuration in July 2024 and in final configuration in November 2024.

Also complete is the new U.S. 41 interchange in its current phase. Final completion will come with Section 2 of the project. Nine new bridges were also built, and seven new bridges are open to traffic now. The other two will open to traffic when the future I-69 bridge is complete. Additionally, the team completed seven rehabilitated bridges, over 85,000 square feet of noise barrier, and over 2 miles of new cross-country alignment.

“We are getting close to the finish line for Section 1, which is incredibly exciting,” Deason said. “Crews are focusing most of their attention on the new U.S. 60 interchange, which is expected to open to traffic this fall. Paving has been underway throughout the corridor, with a lot of progress made this summer. The corridor now has final surface, which means a smoother ride for drivers, and is another sign of being close to completion.

“We still have some aesthetic work underway at the reconstructed KY 351/2nd Street interchange, where gateway signage for the city of Henderson is being installed. Plantings are complete in the area, and flagpoles have been installed. That work was completed this summer.”

Safely maintaining traffic has been a top priority on the I-69 ORX Project, and a carefully structured Maintenance of Traffic (MOT) plan has been implemented.

“The plan begins with the design-build team submitting their proposed traffic plan any time there is an impact to the traveling public,” Deason said. “From there, it undergoes reviews by the project team to ensure both design and constructability are addressed. Once the reviews are complete and all comments are resolved, the plan is approved and distributed to the design-build team and field staff for implementation.

“The design-build team also maintains an active MOT log to detail which approved MOT plans are implemented and active on the job. This is updated weekly and distributed to the project team. This process ensures that traffic control measures are consistent, coordinated, and safe for both the traveling public and construction crews. The information is also shared with the public and stakeholders through our project website, social media channels, e-blasts, and other communications.”

Access to needed supplies in a timely fashion is key to maintaining the project schedule, but this has proved challenging. As is frequently being seen on projects across the country, manpower and the labor market are also challenges.

Existing soil conditions were a concern, but that risk has been mitigated. Flooding was also a concern since this project is being built within a floodway. However, Ragle has been able to complete building the south basin of approximately 180 acres without flooding, and with no additional material required. The contractor has dried soil on the low side of optimal to allow moisture to wick up and stay within tolerances. The contractor also used bridge lifts to overcome poor soil conditions, and crews will break up most of the existing pavement and bridge demolition debris for reuse as embankment material.

Ragle took borrow material from the permanent basins in two different methods, depending on depth of cut and moisture content. It was either placed directly as embankment or laid out to dry.

“All the material for embankments will come from the project site,” Deason said. “Two permanent detention basins along the right of way serve as the main borrow sources. The west basin contains over 400,000 cubic yards, and the east basin over 800,000 cubic yards. The project has average hauls over 6,000 linear feet.”

Weather can always be a challenge during construction, but ORX Section 1 got off to a very strong start in late 2022 with dry and mild conditions. More snow and ice than usual in winter 2024/2025 meant focusing on activities that could be accomplished during inclement weather and finding ways to make up any delays. Heavier rain this past spring and early summer has meant pivoting on some items to when conditions are more favorable, but Section 1 remains on schedule.

On the reconstructed KY 351 interchange, innovation was key to constructing three roundabouts in a highly constrained corridor. The team coordinated around numerous utilities — water, sewer, gas, communications, and power — while maintaining two lanes of traffic and access to four interstate ramps on an active four-lane divided highway. Creative staging and phased construction allowed the work to move forward safely while minimizing impacts to the traveling public.

Jim Gray, Kentucky Transportation Cabinet Secretary, characterizes the I-69 Ohio River Crossing Project as an undertaking that will not only change commutes for residents but will also transform the entire region.

“This is a generational project that will improve travel and safety for drivers in our ‘New Kentucky Home,’” he said. “We are proud of the work that is nearing completion in Henderson. To see this transformational project getting its start in Kentucky is extremely gratifying. When ORX Section 1 is complete late this year, we’ll have drivers traveling on new roadways and bridges in Kentucky, and we know we are moving closer to completing the I-69 connection.”

“Connectivity leads to opportunities,” Deason added. “Providing interstate connectivity between Evansville, Indiana, and Henderson, Kentucky, with the I-69 bridge will mean the faster, safer, and more efficient transit of people and goods in the area. Section 1 of the project is a necessary component to complete this critical connection.

“Approach work is wrapping up in Henderson. Approach work will be complete in Evansville in late 2026. Kentucky and Indiana will meet in the middle with the new I-69 bridge. The transformational project is expected to lead to growth in the community and more economic opportunities with significant announcements already seen in Henderson because of the improved infrastructure that will be in place.

“It’s very rewarding to serve as Project Manager for a project that is going to make such a difference in the entire western Kentucky region for decades to come.”

• Owner: Kentucky Transportation Cabinet
• General Contractor: Ragle, Inc., Newburgh, Indiana
• Designer: Stantec, Lexington, Kentucky
• Development and Preliminary Design: Parsons, Chantilly, Virginia
• Construction Engineering and Inspection: HDR, Omaha, Nebraska
Photos courtesy of I-69 Ohio River Crossing