Hyundai’s expansive manufacturing center near Savannah opened in October, ahead of scheduled road improvements intended to transform an underused I-16 interchange into a vital access point for its 8,500-employee campus.
However, current staffing numbers are significantly lower, with only about 1,500 workers employed at the plant thus far, excluding those involved in constructing an EV battery plant on site.
The traffic situation in the area is already a major concern, as the influx of Hyundai employees intersects with workers from nearby manufacturers, including firearms maker Daniel Defense and vinyl products fabricator Orafol, creating substantial congestion.
Commuters regularly experience long waits, with traffic backups extending onto the interstate shoulders during peak hours.
On a recent morning, workers found themselves waiting more than 12 minutes just to exit the highway coming from the east.
Leaving the factory in the afternoon presents its own set of challenges.
On average, it takes 30 minutes to navigate the 2.5 miles from employee parking lots to I-16, a notable improvement from nearly an hour last fall during initial production.
However, many workers report even longer delays, sometimes lasting 35 to 40 minutes just to clear the frontage road.
Authorities have pointed to several factors contributing to the lag in road improvements.
While Hyundai constructed its 16 million-square-foot facility in just two years, several storms—Tropical Storm Debby, Hurricane Helene, and Hurricane Milton—interrupted road work last year.
Debby brought unprecedented rainfall, Helene uprooted trees and knocked down power lines, and Milton was a precautionary halt despite sparing coastal Georgia from major impact.
Now, over seven months after the factory’s opening, some roadwork is finally reaching completion, with roundabouts and road widening expected to be finished in June.
One of the new features, designed as Georgia’s first peanut-shaped roundabout, aims to facilitate traffic from the plant toward U.S. 280 and I-16 without stopping.
This roundabout is projected to quadruple the traffic capacity in the area.
The schedule for widening exit ramps, however, remains undetermined according to the Georgia Department of Transportation.
An additional I-16 interchange is also planned for construction east of the site, but work is not expected to start until later this year, with a target completion in 2027.
Brent Stubbs, the chief administrator at Hyundai’s factory, referred to the ongoing roadwork as an “inconvenience” but commended the Georgia Department of Transportation and road crews for their efforts in addressing the issues.
He acknowledged the significant challenges in managing traffic flow while simultaneously constructing the plant and its facilities.
Observers note similarities with congestion at the nearby Gulfstream Aerospace facility, where traffic bottlenecks occur during employee shift changes.
Hyundai has implemented some measures to alleviate peak-time congestion, including adjusting manufacturing start times and encouraging office workers to arrive later.
However, many local residents express growing frustration over the situation.
Tammy Castro, an employee at NAPA Triple J Mechanical, located along U.S. 280 south of the plant, voiced concerns that not enough consideration was given to local infrastructure when planning for the plant.
“I don’t think they thought this out ahead of time,” she said, highlighting challenges faced by locals who now avoid the area altogether.
Castro and her co-workers have taken to using alternative routes to reach work, opting for back roads to avoid the heavily congested areas around the factory.
From her home in Eden, just 7 miles away, she detours onto I-16, exiting a mile past the factory and doubling back to reach her workplace.
James Burke, a colleague, follows a similar approach, taking longer routes from his home in Guyton, located to the east of the plant.
Despite their local knowledge, commutes become more stressful as the number of Hyundai employees and other manufacturers increases, causing traffic to spill onto their alternate routes.
One particular detour leads by Ken’s IGA, located approximately four miles north of the factory, which has become nearly impassable during shift changes.
Jackie Davis, a clerk at Ken’s IGA, remarked, “They should have fixed the roads first, before they built the plant.”
She noted that the situation is not only bad, but also deteriorating over time.
The anticipated solution to alleviate the severe traffic pressure is the new interchange planned at the end of Old Cuyler Road, a less-traveled and unpaved path.
This underdeveloped area is flanked by mobile homes, a closed church, and warehouses.
As of now, additional route options remain limited, with the plant’s frontage road ending half a mile from where the new interchange will cross I-16.
Once completed, the new interchange is expected to provide convenient access for those coming to and from Savannah and its surrounding areas.
Traffic planners predict that 5,300 vehicles will use Old Cuyler Road for plant access beginning in 2027.
However, for the time being, it remains a set of blueprints rather than a finished roadway.
Standing on an I-16 overpass overlooking the area, one can see ongoing construction at U.S. 280, symbolizing hope for future improvements amidst the current chaotic traffic situation.
Despite the challenges, Castro acknowledged that the ongoing changes have had some positive effects.
“It’s been good for business,” she said, reflecting on the mix of difficulties and opportunities generated by the situation.
Ultimately, the situation encapsulates the complex interplay between rapid industrial development and the infrastructure needed to support it.
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