I-495 NEXT Express Lanes

Written By Dennis Litvak

Client

LANE Construction / WeBuild Group

Location

I-495 in North Virginia

Year Started

2023 Ongoing

Scope

  • Bridge and roadway demolition

  • Barrier and slab removal

  • Nighttime operations and staged demolition

  • Steel recovery and concrete recycling

The I-495 NEXT project is a major infrastructure upgrade that extends the I-495 Express Lanes by 2.5 miles north toward the American Legion Bridge. As part of the region’s most high-profile transportation initiative, LANE Construction enlisted REMAC to execute critical demolition phases along the corridor, including work adjacent to live traffic, utilities, and active commuter rail.

Services Performed

✅ Structural Demolition

Selective takedown of overpasses, retaining walls, median barriers, and concrete roadway segments using excavators equipped with hydraulic breakers and shears.

✅ Phased Night Work

Demolition scheduled during overnight highway shutdowns to minimize disruption and comply with VDOT safety protocols. All debris was staged and removed before morning traffic resumed.

✅ Steel and Concrete Processing

Steel rebar was cut and bundled on-site. Concrete slabs were broken, sized, and loaded for off-site crushing and recycling.

✅ Traffic Control Coordination

Close coordination with LANE Construction, VDOT, and subcontractors to ensure compliant lane closures, flagging, and shift staging.

Challenges & Solutions

Challenge

Bridge removal over active lanes and adjacent to the WMATA Metro corridor required precision and zero tolerance for falling debris.

Solution

RemacUSA implemented controlled pumping and HEPA-filtered negative air systems. All debris was hand-bagged or wet-vacuumed under negative pressure to prevent airborne fiber release.

Materials Recycled

  • Reinforced steel separated and recycled through regional scrap facilities

  • Concrete loaded and shipped for crushing and reuse

  • Asphalt millings recovered for reuse in future paving

Final Outcome

Our crews have demonstrated adaptability, speed, and strict adherence to VDOT, LANE, and project safety requirements.

The partnership continues through 2025, with REMAC contributing to the corridor’s phased buildout: supporting structure removals, material recovery, and contractor coordination for future stages.

Dennis Litvak
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USDA Beltsville Agricultural Research Center