Nearly 70 percent of all Pennsylvania Turnpike traffic operates within the system’s eastern third, placing heavy congestion pressures on toll plazas during peak periods. The Valley Forge Interchange (Milepost 326) was one of the most congested, with queues extending onto the mainline roadway during rush hour. To address this critical chokepoint, the Pennsylvania Turnpike Commission advanced a major highway and tolling improvement program. STV provided multidisciplinary design services for this design‑build effort, enhancing plaza capacity, modernizing tolling systems and improving roadway efficiency at one of the Turnpike’s busiest gateways.
What challenges did STV address?
The existing toll plaza could not accommodate the high demand from commuter and regional traffic, resulting in backups that affected safety and mobility. Expanding the plaza required careful planning to integrate new lanes with existing structures, extend canopy systems and upgrade drainage, utilities and power while maintaining live tolling operations. The project also required coordination of complex tolling, ITS and electrical systems in a tight work zone.
What solutions did STV deliver?
STV designed four new entrance lanes and toll booths, converted two existing entrance islands into exit islands and provided full MEP, structural, civil and architectural support. The team extended the steel canopy over new and existing lanes, installed 1,500 feet of concrete barrier and upgraded plaza utilities, including new power service, duct banks, UPS systems and lighting. STV also enhanced roadway drainage by lowering pavement near inlets to increase capacity and designed conduit routing for E-ZPass and lane-control signaling.
How does this project benefit the community?
The improvements reduce congestion, shorten wait times and improve safety by eliminating back‑ups that once spilled onto the Turnpike mainline. Modernized tolling systems support faster, more reliable travel for commuters, freight operators and visitors traveling through the King of Prussia region.
Key stats and accolades
- Four new entrance lanes with new toll booths
- Two entrance islands converted to exit islands
- Extended canopy system and 1,500 feet of new concrete barriers
- Enhanced drainage, power service and E‑ZPass infrastructure
