Summary: On June 11, 2023, a tanker explosion beneath I‑95 in northeast Philadelphia destroyed a 104‑foot, four‑lane section and killed the driver. PennDOT and contractor Robert Buckley executed a rapid two‑stage plan—using ultralight foamed‑glass aggregate and nonstop crews—to backfill and pave a temporary roadway. With 85 escorted loads and several construction innovations, three lanes each way reopened in 12 days (June 23, 2023), while permanent repairs continued into 2024.
I‑95 Rebuilt in 12 Days: The "Philly Special" That Restored a Vital Highway After a Deadly Tanker Explosion
Summary: On June 11, 2023, a tanker explosion beneath I‑95 in northeast Philadelphia destroyed a 104‑foot, four‑lane section and killed the driver. PennDOT and contractor Robert Buckley executed a rapid two‑stage plan—using ultralight foamed‑glass aggregate and nonstop crews—to backfill and pave a temporary roadway. With 85 escorted loads and several construction innovations, three lanes each way reopened in 12 days (June 23, 2023), while permanent repairs continued into 2024.
08:51 AM, 11/15/2025Society
Inside the Collapse and the Race to Rebuild
June 11, 2023: In the predawn hours, Nathaniel “Nate” Moody, a 53‑year‑old Army veteran and long‑time trucker, was driving an 18‑wheeler carrying 8,500 gallons of gasoline on I‑95 in northeast Philadelphia. As he turned onto westbound Cottman Avenue the tanker flipped, ruptured and exploded. The fire reached temperatures estimated as high as 2,500°F, cooking the steel girders under the highway. In less than 15 minutes a 104‑foot, four‑lane span collapsed onto Cottman Avenue; Moody died at the scene.
Immediate response
PennDOT, Philadelphia emergency services and state officials mobilized within hours. With flames shooting from sanitary drains and worries about runoff into the Delaware River, crews worked to contain environmental hazards and secure the scene. By about 8:45 a.m. the fire was under control and engineers began assessing structural damage: an unusual quarter‑span failure, badly damaged abutments, destroyed bearing pads and unknown condition of a 60‑year‑old box culvert beneath the road.
The challenge and the plan
Because a full permanent rebuild would take months, engineers and contractors pursued a two‑stage approach: build a safe temporary roadway across the damaged center span to restore traffic quickly, then construct the permanent lanes on either side and replace the temporary lanes afterward. Around 9 a.m., contractor Robert Buckley and PennDOT agreed on a bold concept—later nicknamed the "Philly Special": backfill the center opening with a lightweight, engineered foamed‑glass aggregate and pave temporary lanes on top.
Material choice and logistics
Conventional fill would have overloaded aging utilities and the old culvert. Buckley proposed an ultralight foamed‑glass aggregate supplied by AeroAggregates (Eddystone, PA): about 20 lb/ft3 versus 120–130 lb/ft3 for typical fill. The plant ran 24/7; with state police escorts, crews delivered 85 loads—approximately 8,000 cubic yards (roughly 8 million glass bottles worth) —instead of an estimated 600 truckloads of regular fill.
Construction innovations
Crews laid high‑strength geogrid and placed the foamed glass in 18‑inch lifts, compacting and reinforcing between layers. To reach skewed corners, Buckley improvised an "elephant trunk" sleeve on a conveyor and controlled pours remotely. Precast F‑shaped barrier units and bifurcated median barriers were diverted or accelerated from suppliers. Work continued day and night through rain and setbacks, with an on‑site command center on Cottman Avenue and hundreds of workers coordinated across contractors and agencies.
Political and federal involvement
Governor Josh Shapiro issued a disaster declaration to unlock federal funds. Transportation Secretary Pete Buttigieg toured the site, and President Joe Biden flew over on June 16, pledging federal support. The project drew national attention and unusually close public‑private cooperation under enormous time pressure.
Finishing touches and opening
As concrete curing and striping neared completion, an overnight rain threatened the schedule. Secretary Carroll arranged for an Air Titan jet dryer from Pocono Raceway (requiring ~5,000 gallons of kerosene) to dry pavement so lane markings could be applied. On June 23, 2023—12 days after the explosion—the temporary southbound lanes opened at about 12:30 p.m., followed by northbound lanes an hour later. The temporary roadway provided three 11‑ft lanes each way, no shoulders, and a reduced 45 mph limit; permanent reconstruction was completed in May 2024.
Aftermath and recognition
Buckley & Co. raised funds for Nate Moody's family; local sports teams and unions contributed to a trust for his daughter. Workers who toiled around the clock were publicly celebrated—honored at a Phillies game and at a gubernatorial reception—recognizing the extraordinary coordination and effort that returned traffic to one of the East Coast's busiest arteries in days rather than months.
Key facts: 8,500 gallons of gasoline; 104‑ft span collapsed; fire up to ~2,500°F; 85 loads (~8,000 yd3) of foamed‑glass aggregate; 12‑day emergency rebuild; temporary lanes opened June 23, 2023; permanent work finished May 2024.