Mainline Widening Construction Activities
Current Activities: Through Early 2025
Project Substantially Completed
- Complete drainage basin construction
- Complete punch-list activities
Design & Construction Details
Total Reconstruction Project
Construction Update: Final
Widening and Reconstruction Project Substantially Completed
Winter 2024-25 – The Pennsylvania Turnpike Commission’s $117 million project to reconstruct and widen Interstate 76 between the Valley Forge Service Plaza (MP324) and Valley Forge Interchange (MP 326) has been substantially completed, marking the end of over three years of construction.
The Turnpike’s contractor completed paving operations on the center area of the highway in the early fall and reopened the roadway to six lanes (three in each direction) in late October (see below).
In addition to widening and reconstructing Interstate 76, this project, which began construction in fall 2021, included the replacement of the bridges carrying the Turnpike over Route 422/N. Gulph Road, Thomas Road (see below), and Glenhardie Road (see bottom picture). A new stormwater management system, including new drainage pipes and 6 aboveground stormwater basins, also was installed. The project also included milling and overlaying portions of the Turnpike east of the Valley Forge Interchange and side roads.
Other work completed under this project consisted of the installation of new sound walls, retaining walls, 2 arch culvert extensions, and sign structures throughout the project corridor.
During reconstruction of the center area, the existing four lanes of concrete pavement were excavated and recycled on-site for reuse as the sub-base course of the new eastbound and westbound pavement.
This project is one of the Commission’s seven projects to widen and reconstruct I-76 from the Morgantown Exit (MP 298) and the Valley Forge Interchange (MP 326). A separate contract to widen and reconstruct the highway between the Downingtown Interchange (MP 312) and the Valley Hill Road Bridge (MP 316) is under construction, and a new project that will widen and reconstruct the roadway between the Route 29 Interchange (MP 320) and Valley Forge Service Plaza (MP 324) is anticipated to begin in 2025. Information on all of the Turnpike’s construction projects can be found on the Commission’s Major Design & Construction Projects page.
Motorists may encounter occasional daytime lane closures on weekdays between 6:00 am. and 5:00 p.m. into early 2025 while the contractor completes punch-list items and drainage basin work.
Travel restrictions will be publicized in advance via Travel Advisories that will be sent to email subscribers and posted to the website. Click here to sign up for the PTC 324-326 email list.
Construction Staging
Prep Stage: Fall 2021 - COMPLETED
- Install advance signing
- Reconstruct inside shoulders
- Place construction barrier along outside edges of existing EB and WB lanes
- Install environmental controls
Travel Impacts:
- Maintain two lanes in each direction
- Periodic off-peak single-lane closures in either or both directions
Stage 1 Construction: Late 2021 to Late 2023 - COMPLETED
- Excavation for construction of new EB and WB outside third lanes and shoulders
- Install stormwater drainage pipes and inlets and drainage basins
- Construct new EB and WB third lanes
- Construct outside sections of new bridges over Thomas Road, Glenhardie Road, and U.S. 422/N. Gulph Road
Travel Impacts:
- Maintain two EB and WB lanes on the Turnpike
- Periodic off-peak single-lane closures in either or both directions
- Thomas Road, Glenhardie Road one lane with temporary traffic signals
- Thomas Road short-term detour in early 2022 for pipe installation
- No shoulders on U.S. 422 at Turnpike overpass
Stage 2 Construction: Late 2023 to May 2025 - CURRENT STAGE
- Shift two lanes of EB and two lanes of WB traffic to the newly reconstructed EB and WB lanes and shoulders
- Remove existing median barrier
- Excavate existing EB and WB travel lanes
- Install stormwater drainage pipes and inlets
- Reconstruct the existing two EB and WB travel lanes
- Resurface a one-mile portion of I-276 east of Valley Forge Interchange (MP 326)
- Adjustment of pavement markings on I-276 and Valley Forge Interchange
- Install new overhead signs and sign bridges near Valley Forge Interchange
- Construct new median, median barrier
- Construct inside sections of new bridges over Thomas Road, Glenhardie Road, and U.S. 422/N. Gulph Road
Travel Impacts:
- Maintain two EB and WB lanes
- Periodic off-peak single-lane closures in either or both directions
- Thomas Road, Glenhardie Road one lane with temporary traffic signals
- No shoulders on U.S. 422 at Turnpike overpass
Early Construction Activities
Advance Tree Clearing Contract
The PTC completed a tree clearing contract in April 2021 within the limits of their right-of-way in advance of the upcoming construction project. The reason for performing the work at this time is due to environmental regulations, which require that cutting down trees greater than 4 inches diameter must occur between the months of November and March due to the presence long eared bats, which are an endangered species in this region. In order to not impact the schedule of the upcoming construction project, the PTC initiated a separate contract to remove the trees within the allowable time of year. After the trees are cut down, they are being collected and turned into wood chips. Since the project area is within the Spotted Lantern Fly (SLF) quarantine area, trees and branches cannot be transported out of the quarantine area. All trees and branches must be chipped and left sitting in piles for several days to generate heat to kill the SLF eggs. Wood chips are then being collected and removed. The PTC will remove all remaining stumps and perform any needed residual tree clearing within the appropriate restrictions as part of the upcoming construction project.
Asphalt Patching and Resurfacing Contract
A project to patch and resurface the existing Turnpike roadway between the Mill Road overpass and Valley Forge Interchange started on April 19, 2021. The contractor is currently working on the eastbound Turnpike, working their way from the area of the Mill Road overpass towards the Valley Forge Interchange. The eastbound work is anticipated to be complete by the end of April and will then begin working westbound. The overall completion date for this pavement patching work is July 23, 2021 but may be completed as early as Memorial Day. The work needs to be performed at night due to lane closures that are required during off-peak hours.
This work is not part of the upcoming reconstruction and widening project but is needed to make sure the existing roadway will remain in good condition over the next several years during the widening project.
Reconstruction and Widening Project Schedule
The reconstruction and widening project is going out to bid in July 2021 and construction is expected to begin in September 2021. Construction is anticipated to take approximately 3 years, with the Turnpike open to 6 lanes of traffic by November 2024. There may be some additional landscaping and seeding that needs to be completed in the Spring of 2025 depending on weather and timing. The PTC's contracting methods, which are widely used across the industry, are to design and sequence the project, but provide general guidance in the way of timing. This is done to allow flexibility to the Contractor to get the best quality project in a reasonable timeframe. Therefore, the timing of specific construction activities will be determined by the Contractor. The Contractor will provide a more detailed schedule once the project is awarded and regular updates will be posted on the project website as construction progresses to provide advanced notice of specific work activities.
The reconstruction of the Turnpike bridges over Thomas and Glenhardie Roads is estimated to begin in May of 2022 and continue through May of 2024. Both Thomas and Glenhardie Roads will require single lane conditions underneath the bridges for a period of time, in order to provide sufficient room for the bridge construction. Temporary traffic signals will be installed on each side of the bridge to control the flow of traffic. A closure of Thomas Road to all traffic will occur in the Fall of 2021 for installation of a storm drain pipe and traffic will be detoured using Glenhardie Road. It is anticipated this closure will last approximately one week. Intermittent short-term closures at both sites will occur as needed for specific demolition and erection operations. Please refer to the link below for a preliminary construction and detour schedule. The website will be updated during construction to provide advance notice on the timing of these restrictions.
The sound barriers for this project will be built during the first stage of construction, which will take approximately 2 years to complete between the Fall of 2021 and end of 2023. Not all sound barriers will be constructed at the same time, however they will all be constructed by the end of 2023. The location of the sound barrier, relative to the Turnpike and construction access, influences the decision on when a given section of barrier can be constructed.
Excess Excavation Area
Construction of the widening and reconstruction project will result in excess soil and rock that needs to be permanently placed within the project limits. The PTC has identified an area within their property at the Valley Forge Service Plaza where the contractor can place this material, which is shown on the map using the link below.The excess excavation areas may be up to 35 feet in height. The existing berm behind the service plaza is 18 feet high.
Bridge Replacements
This project includes the replacement of three mainline bridges, which carry the Turnpike over local or state roads. The following structures will be replaced during the mainline construction:
- Thomas Road
- Glenhardie Road
- SR 0422 and North Gulph Road
Project Schedule
