Volvo EC480EL Powers Hurricane Recovery in Bat Cave, NC
In the wake of Hurricane Helene in September 2024, one of the most urgent rebuild projects is taking place in Bat Cave, North Carolina, a mountain town where floodwaters washed away U.S. 64.
Today, Blythe Construction is leading the $32 million effort to restore the highway, contracted by the North Carolina Department of Transportation (NCDOT). The work includes slope stabilization, road widening, and extensive drainage improvements to protect against future flooding. The rebuilt section is expected to open to two-lane traffic by September 2026, with final environmental restoration completed in mid-2027.
A Jobsite Like No Other
The hurricane’s force ripped away huge sections of roadway along Reedypatch Creek and the Rocky Broad River, leaving steep, unstable slopes and limited access for equipment. Blythe’s crews are placing roughly 30,000 tons of Class 7 rock to reinforce the roadbed, along with concrete knee walls and upgraded stormwater systems.
Given the site’s elevation, 20 to 40 feet above the creek bed, traditional bulldozer work isn’t possible. Instead, crews are using excavators to build rockfills and maneuver heavy materials with precision.
Volvo EC480E: Heavy Lifting in Tight Spaces
Central to the operation is the Volvo EC480E crawler excavator, delivering the reach, stability, and breakout force needed to handle large rock in challenging mountain terrain. From loading material into Bergmann carriers to performing delicate slope work, the EC480EL is proving its value in one of the most complex recovery jobs North Carolina has faced in years.
Blythe is also using an innovative grout-filled rockfill technique, locking rock structures together to withstand future storm surges and river scouring—a method expected to extend the lifespan of the repairs.
“The people up here have been dealing with this one-lane road and this big mess for almost a year now,” said Blythe Superintendent Mark Spradling. “They’ve been through a lot, so we’re working hard to get U.S. 64 back to two lanes as soon as possible.”
Building Resilience for the Future
Once completed, this project will restore a vital transportation link through Hickory Nut Gorge, help local businesses recover, and strengthen the region’s resilience against extreme weather.
As the Southeast’s authorized Volvo Construction Equipment dealer, Ascendum Machinery is proud to support the contractors and crews working tirelessly to rebuild stronger, safer roads for our communities.
