Raleigh’s Complete 540 and Transportation Overhaul: What It Means for Freight and Trailer Operations

The Complete 540 project, a $1.3 billion expansion of the Triangle Expressway, along with other mobility upgrades, is re-routing traffic and creating new opportunities for more efficient logistics. For fleet managers, dispatchers, and drivers, these changes affect travel times, trailer wear, and long-term planning.

Hale Trailer Brake and Wheel serves fleets across North Carolina with rentals, sales, parts, and service. As Raleigh’s road system transforms, our role is simple: keep trailers road-ready so freight keeps moving.

The Complete 540 Project: A New Outer Loop for Raleigh

What Is Complete 540?

The Complete 540 project extends the Triangle Expressway to complete Raleigh’s outer loop. Phase 1 opened in fall 2024, connecting N.C. 55 Bypass in Apex to I-40 near Garner, about 18 miles of new toll road designed to pull traffic off local arterials and I-440. Phase 2 is now underway, stretching the loop further east to I-540/U.S. 64/U.S. 264 in Knightdale, with six interchanges, 24 bridges, and 14 culverts included in the design. Construction started in 2024 and is expected to wrap up by 2028.

Why the 540 Project Matters for Freight

The project gives truckers an alternate route that avoids bottlenecks on I-40 and I-440. For heavy freight moving between industrial corridors in Garner, Clayton, and Knightdale, this means shorter idle times and fewer miles on surface streets. Long-haul carriers also gain a more direct bypass around Raleigh’s urban core, keeping rigs moving at consistent speeds.

How Complete 540 Affects Trailer Operations

Reduced Congestion, Better Schedules

Traffic congestion is one of the largest hidden costs in trucking, adding billions in wasted fuel and driver hours across the U.S. every year. By drawing cars and trucks off overloaded corridors, Complete 540 allows dispatchers to tighten arrival windows and reduce late deliveries. This is especially valuable for refrigerated freight, where a missed appointment can compromise a load.

Interchanges Built for Modern Freight

The new interchanges are designed for today’s larger vehicles, with longer merge lanes and better turning radii. That’s good news for 53-foot dry vans and flatbeds that often struggle with short ramps or tight curves on older sections of Raleigh’s road network.

Tolling and Fleet Budgets

Complete 540 is an all-electronic toll road. For fleets, this means budgeting for tolls but saving on fuel and maintenance by cutting idling and stop-and-go driving. Many carriers will find that tolls pay for themselves once they run the math on reduced wear and improved scheduling.

Other Transportation Projects and Freight Impact

Bus Rapid Transit (BRT) and Freight Movement

Raleigh’s Bus Rapid Transit (BRT) system is designed for commuters, not freight. But its construction and operation impact trucking in two ways:

1. Construction Phases: Road work along BRT corridors, such as New Bern Avenue, can create detours that impact last-mile delivery routes.
2. Traffic Flow: Once operational, BRT will shift commuter traffic out of regular lanes, potentially freeing space for trucks on parallel roads. For local deliveries into downtown Raleigh, that means fewer conflicts with car traffic in certain corridors.

Rail and Intermodal Connections

The region is also investing in rail through projects like the Raleigh–Richmond S-Line corridor, backed by a $1.09 billion federal grant. While primarily focused on passenger service, these upgrades free up track capacity that can improve freight reliability. For trucking, this creates opportunities in intermodal drayage, or trailers moving containers between rail yards and warehouses.

Short-Term Challenges for Freight Operators

Construction Zone Realities

Until 2028, carriers should expect:

• Lane shifts and narrowed shoulders along key work zones.
• Night work that reduces visibility and requires extra caution for wide trailers.
• Temporary detours affecting local deliveries, especially near interchanges being rebuilt.

Every mile in a work zone demands trailers that track straight, brake evenly, and handle stop-and-go without issue. Preventive maintenance is crucial for minimizing downtime.

Equipment Strain

Rough temporary pavement and detours can take a toll on suspensions, brakes, and tires. Extendable flatbeds, step decks, and lowboys in particular feel the stress when navigating uneven joints or temporary ramps. Regular inspections help catch issues before they sideline a load.

Long-Term Benefits Once Projects in Raleigh Wrap

Faster Freight Flow

By 2028, Raleigh’s freight network will see a dramatic improvement in travel time reliability. Truckers will have a full loop that connects I-40, I-87, and I-95 with fewer choke points.

Safer Trailer Maneuvers

New bridges and interchanges are designed with today’s freight in mind, cutting down on tight turns and sudden merges. This makes life easier for long-wheelbase trailers and reduces the risk of costly accidents.

Lower Maintenance Costs Over Time

Smoother pavement and consistent speeds mean fewer pothole hits, less brake wear, and more even tire aging. Over the life of a trailer, those small savings add up to real money.

How Hale Trailer Supports Raleigh’s Freight Community

Trailer Rentals that Match the Job

Whether it’s a dry van for regional runs, a reefer for food distribution, or a flatbed for construction equipment, Hale Trailer has the rental inventory to match Raleigh’s evolving freight routes. As new road segments open and traffic patterns shift, our team ensures trailer swaps are seamless, so your fleet never skips a beat.

New and Used Trailer Sales for Every Operation

For fleets ready to invest, Hale Trailer offers one of the largest selections of new and used trailers in the region. From top-of-the-line models fresh from the factory to well-maintained used trailers that fit tighter budgets, our sales teams help operators find the right equipment for their business. Whether you’re scaling up to handle Raleigh’s growing freight demands or replacing older gear, we’ll connect you with trailers built to work as hard as you do.

Parts and Service to Handle Work Zone Stress

Construction detours and temporary joints are tough on equipment. That’s why Hale Trailer’s service teams focus on alignments, brake inspections, and suspension checks to keep trailers running smoothly. At the parts counter, we keep shelves stocked with essentials (chambers, drums, landing gear, lighting, and a whole lot more) so drivers can get what they need without downtime.

A Partner in Long-Term Planning

We’re not just here for emergencies. As Raleigh’s infrastructure evolves, Hale Trailer helps fleet managers plan ahead, whether that means prepping trailers for new toll routes, keeping specialized equipment available for construction projects, or mapping out when it makes sense to rent, buy, or service trailers.

Preparing Your Fleet for Raleigh’s Future

Raleigh’s Complete 540 project and related transportation upgrades are setting the stage for a more connected, freight-friendly region. Yes, the next few years will bring lane closures, detours, and strain on equipment. But when the loop is finished and traffic patterns settle, fleets that plan ahead will benefit from faster runs, safer routes, and lower operating costs.

Hale Trailer Brake and Wheel in Raleigh is ready to keep your trailers in shape for every mile. Whether you’re running local deliveries or hauling freight across the Triangle, our rentals, sales, parts, and service give you the support to keep freight moving.