STV’s design of the second phase of the Betsy Ross Interchange (BRI) program earned a project of the year award from the Delaware Valley chapter of the American Society of Highway Engineers (ASHE). STV accepted the award alongside representatives from the Pennsylvania Department of Transportation (PennDOT) and project partners from Urban Engineers and JBC Associates, Inc.

The project is a key piece of PennDOT’s most extensive highway improvement program, which aims to reconstruct and revive I-95 in Pennsylvania. The four-phase BRI project strives to create a safer, more efficient interchange for the over 160,000 vehicles that use it daily.

STV’s team of designers is supporting PennDOT with preliminary engineering, final design and construction support services throughout all four phases. The second phase, completed in February 2024, focused on a three-level interchange that would provide enhanced safety and stability for drivers. STV’s team leveraged innovative structural systems for the interchange ramps to meet the constrained site conditions. This included designs for replacing bridge spans over Frankford Creek, and Conrail, and NJ TRANSIT rail lines, as well as underneath PECO’s high-voltage transmission lines.

To meet these challenges, STV designed the nation’s first steel curved tubular flange girder (TFG) span that was then piloted by PennDOT. The project also constructed the tallest prefabricated T-Wall system in Pennsylvania. The team developed a variety of temporary support systems for existing structures, allowing the construction to maintain traffic, reduce detour durations, and retain existing infrastructure. These temporary systems facilitated the replacement of an existing pier while the existing bridge remained in place.

“To say that this is one of the most consequential projects of my career feels like an understatement,” said Alexander Houseal, vice president and district manager at STV. “Betsy Ross Interchange is emblematic of the efforts of PennDOT to improve one of the busiest interstates that courses through Pennsylvania. This interchange, located right outside of Philadelphia, will improve commutes for thousands of people. Our team is truly honored to receive this award from ASHE Del-Val.”

Public engagement and input were crucial throughout the project, informing several aesthetic features like the formliners along the ramps. Given its historic location in Philadelphia, the formliners are intended to represent the waving stripes of the American flag – a nod to the namesake of the interchange. This feature came from PennDOT’s extensive community outreach and collaboration with community groups, businesses and the public.

The program recently entered construction of the third phase, which will widen and reconstruct northbound I-95, as well as rehabilitation and replacement of several ramps and bridges. STV’s team is busy designing the remaining phases that will achieve final completion in 2032.