Proj Overview

PROJECT OVERVIEW

The Pennsylvania Turnpike Commission’s (PTC) Open Road Tolling Expansion (ORT) modernizes its tolling operations along the 565-mile extents of the PA Turnpike. It utilizes overhead gantry structures to collect the tolls with no need for traffic to slow down. As part of the network through multiple contractors, PennStress produced 70 architectural precast columns to support the steel framing needed for the overhead structures. Each precast column is a tapered column between 22’ and 34’ with a wrapped ashlar stone design using a form liner system from Architectural Polymers. The precast columns enabled quick implementation, long-term performance, and a cohesive, high-quality corridor appearance.

PRECAST SOLUTION

PennStress prefabricated the gantry columns under PTC’s rigorous standards. The remote manufacturing allowed for site work to be completed uninterrupted, minimizing on-site construction time, a unique benefit of precast solutions. The connection to the foundation was completed using NMB Splice Sleeves cast into the columns allowing for a quick column erection and high performance precast to foundation connection. The use of precast columns provided structural performance and design flexibility that cast-in-place methods cannot easily achieve, which include architectural ashlar finishing by utilizing form liners supplied by Architectural Polymers. This ensured a consistent visually appealing result while maintaining ultra-precise tolerances for structural performance.

Additionally, this solution aligned with the Turnpike’s goals of durable, low-maintenance, and resilient infrastructure. By utilizing prefabrication, architectural finish, and rapid installation, the Turnpike's choice of precast proved to be a versatile solution for updating tolling infrastructure with economic and logistical efficiency.

 

Project Team

Owner

PA Turnpike Commision

PCI-Certified Precast Producer

PennStress

General Contractor 

Allison Park Contractors

Formliner Manufacturer

Architectural Polymers

Key Project Attributes

  • The 70 precast columns ranged from 22’ to 34’ in height, demonstrating PennStress’s capability to deliver large, structurally complex , architecturally aesthetic precast elements with precision.
  • Ashlar form liners from Architectural Polymers provided a durable, stone-look façade directly onto the columns.

Project/Precast Scope

  • PennStress produced and delivered 70 precast concrete gantry columns to support the overhead ORT structures along the Pennsylvania Turnpike.
  • The installation took place along 565 miles of the turnpike.