Project BACKGROUND
ALDOT is widening an eight-mile stretch of I-65 between Alabaster and Calera to improve traffic flow, increase capacity, and support long-term growth along one of Alabama’s busiest corridors. The project is funded through the Rebuild Alabama initiative, this three-phase, $143 million project includes adding a third travel lane in each direction, expanding shoulders from 4 to 14 feet, and widening multiple structures to support increased capacity.
The project also includes replacing eight bridges, constructing new retaining walls, and adding an inside median lane near Exit 231 in Cal era. These upgrades expand the roadway footprint and prepare the corridor for long-term growth. With daily traffic exceeding 50,000 vehicles, the widening is expected to ease congestion and provide a safer, more reliable route for travelers.
The CHALLENGE
Building new lanes in the center of one of Alabama’s busiest highways brings significant traffic, safety, and operational challenges. Crews operate beside narrow, barrier-lined lanes with no shoulder space, and keeping drivers at the posted 45 mph work zone speed limit has been one of the most persistent challenges, especially during the May–August peak travel season when congestion spikes. All major traffic shifts must be completed at night, and the movement of heavy construction vehicles and haul trucks add additional safety concerns.
The project requires continuous coordination between ALDOT, the contractor, and multiple subcontractors as grading, traffic shifts, and structural improvements advance simultaneously. ALDOT also maintains strict oversight of all materials to ensure they meet required specifications, adding another layer of coordination across active crews and timelines.
The SOLUTION
We maintain a long-standing partnership with Dunn Construction, the project’s primary contractor for the southern section of the project (Exit 231 to Exit 234), serving as their go-to supplier for raw stone for their crushing plant located at our Longview Operation. This project required roughly 150,000 tons of asphalt aggregate, using #67s, #78s, #8s, No. 10 screenings, and outsourced sand, and another 150,000 tons of 825B base material.
Our proximity to the project site along with Dunn Construction’s established crushing setup, created a major operational advantage. Efficient loadout processes allowed trucks to enter, load, and exit in under 10 minutes, enabling roughly 80 trucks per day to deliver 1,000 to 1,200 tons of material, supporting steady progress and keeping the production schedule on track.
IMPLEMENTATION
Since construction began in February 2025, we have provided consistent shot rock supply to support Dunn Construction’s crushing plant, ensuring they have the material and quality control needed for accurate bidding and reliable scheduling. Strong communication between our two operations and the continuous delivery of shot rock allowed our team to provide proactive support. By adapting quickly to changing material needs and resolving technical adjustments with minimal proctor changes, we’ve helped maintain momentum across every phase of this project, ensuring progess continues to move ahead of schedule.
RESULTS
With the project well on track for its 2028 completion, construction continues to advance through major milestones, including multiple bridge replacements, new retaining walls beneath existing structures, and significant progress on additional travel lanes. Dependable material availability for asphalt and base mixes improved coordination between crews, strengthened quality control, and helped keep the widening on schedule. Once all three phases are complete, drivers will benefit from six lanes spanning 60 miles of expanded roadway.
