STV’s Chicago team has officially begun its construction management (CM) and construction inspection (CI) work in support of the I-490/IL 390 Interchange Project, a key component of the Illinois Tollway’s Elgin O’Hare Western Access Project to connect I-90, IL 390 and I-294 via construction of the new I-490 Tollway. This ambitious initiative aims to revolutionize travel in Chicago’s western suburbs by addressing long-standing transportation bottlenecks and, for the first time, providing direct western access to O’Hare International Airport property.
“At its core, this project is about improving connectivity and delivering meaningful benefits to travelers,” said Gregory Ferraro, PE, senior engineer at STV. “By creating a direct link to O’Hare from the west, we’re reducing travel times and congestion and providing a much-needed new option for motorists navigating the region.”
The new I-490 Tollway, a $2 billion investment, is a six-mile corridor connecting I-294 (the Tri-State Tollway) in Franklin Park at its southern end to I-90 (the Jane Addams Tollway) in Des Plaines at its northern terminus. Running along the western edge of O’Hare, the I-490 corridor will feature connections to York Road, Irving Park Road, the Illinois Route 390 Tollway and the airport itself.
At the heart of this initiative is the construction of a full-access interchange between the new I-490 Tollway and IL 390. This $534 million interchange includes 16 ramps, 15 bridges and three miles of mainline roadway, delivering unprecedented mobility on O’Hare’s west side.
STV is providing CM and CI services for six interchange ramps and bridges of this interchange, which entered construction in November 2024. These include four new flyover ramps connecting the Illinois Route 390 and I-490 Tollways, as well as two new bridges providing direct access to O’Hare’s western edge. The project also involves earthwork, drainage improvements and retaining wall installations.
The construction process presents unique challenges, as the six new structures are crossing York Road and two active freight rail lines – Canadian Pacific Kansas City (CPKC) and Union Pacific (UP) – which run parallel to the I-490 corridor. STV is coordinating construction activities among multiple stakeholders, including the Illinois Department of Transportation (IDOT), Cook County Department of Transportation and Highways (CCDoTH), DuPage County Division of Transportation (DuDOT) and the railroads. Construction activities are carefully scheduled to align with less active periods on the rail lines and are paused when trains are in operation, adding to the project’s complexity.
The I-490/IL 390 Interchange Project moved into construction in 2019 and has required extensive coordination for permitting, railroad agreements and airspace rights. The most recent milestone clearing the way for construction progress was the approval to lift aviation approach lighting near O’Hare, where six east-west runways end close to the new tollway. The interchange is scheduled to be completed by the end of 2027.
Once finished, the new I-490 Tollway will reshape transportation around O’Hare and beyond. By addressing critical bottlenecks, reducing congestion and introducing direct western access to O’Hare, the project will save travelers significant time and effort.
