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Secaucus Maintenance Facility Prototype Development

Modular prototype serves as cornerstone of NJTA’s $500 million Facilities Improvement Program.
  • Two-story maintenance building with concrete exterior - Gannett Fleming.

    The Secaucus Maintenance Facility was the first to employ the prototype design, setting the standard for 14 subsequent buildings.

  • Three-dimensional diagram showing colored blocks of space within the interior of a building - Gannett Fleming.

    A kit of parts supports the standardization of administrative and vehicle maintenance areas.

  • A large concrete wall panel suspended from a crane is lowered into place at a construction site - Gannett Fleming.

    Precast wall panels are sized to allow for off-site manufacturing and assembly at the construction site.

  • Two-story concrete wall sections create the exterior of a maintenance building - Gannett Fleming.

    Precast concrete walls create a load-bearing exterior skin, allowing greater flexibility for the interior layout.

  • Two-story maintenance bay with garage doors, equipment, and two maintenance vehicles that are being serviced - Gannett Fleming.

    The two-story maintenance bays are flooded with natural light from the clerestory windows above the garage doors.

  • Interior hallway with an elevator and office space - Gannett Fleming.

    Administrative areas provide offices, conference rooms, and crisis management spaces, along with dormitories for on-call employees.

New Jersey Turnpike Authority

Secaucus, New Jersey

Our Role
Architecture, Structural, Civil, Mechanical, Electrical

18,000 sq. feet
Construction Cost
$13 million
New Construction
4 years
  • The prototype’s modular design simplifies site-specific planning, saving time and money
  • Precast concrete walls create a durable, low-maintenance, and efficient building envelope
  • The prototype program has allowed NJTA to replace 15 aging facilities in under five years
  • Modern working conditions enhance the health, safety, and welfare of employees
  • The standardized facility design creates operational and staffing efficiencies for NJTA.

The New Jersey Turnpike Authority’s (NJTA) 1950s-era maintenance facilities were beyond their useful life, undersized, and in poor condition. Recognizing the need for a complete overhaul, NJTA hired Gannett Fleming to conduct a statewide assessment and develop a prototype design to replace 15 outdated facilities. NJTA needed a cost-effective plan that could adapt to the unique sites and needs of both Turnpike and Parkway maintenance districts, with buildings ranging in size from 12,000 to 40,000 square feet. 

The solution was a modular design using precast concrete wall panels that provides both durability and flexibility. The prototype offers a standard kit of parts to plan administrative areas and vehicle maintenance bays. This modular approach streamlines site-specific planning, saving time and money. It enables certain functional spaces to be replicated from site to site, while other program spaces can be larger or smaller as needed. The precast walls create a load-bearing exterior skin, allowing greater interior layout flexibility. Off-site panel production reduces weather impacts, improves quality, and expedites construction. The Secaucus maintenance facility prototype was successfully adapted for 14 subsequent facilities, allowing NJTA to quickly create modern and equitable working conditions for its crews throughout New Jersey.

What We Did

Gannett Fleming led the development of the prototype maintenance facility design, providing architecture, structural, civil, mechanical, and electrical engineering. To assist NJTA in standardizing its operations, our team held extensive meetings with administrators and maintenance staff to understand program requirements and facility use across the state. NJTA wanted a design that was efficient, flexible, cost-effective, energy-efficient, sustainable, durable, and low maintenance. The prototype achieved these goals. The kit of parts provides tools to promote the efficient use of space. Administrative or maintenance modules can be added or removed from the design to meet the specific needs of each facility. The concrete precast panels are durable, low maintenance, and energy-efficient.

After the original prototype was built in Secaucus, Gannett Fleming worked with NJTA to refine it and begin the process of implementing the design at 14 new facilities across the state. Four design contracts were awarded, including one to Gannett Fleming to complete four more new facilities at other maintenance districts. Our designers developed the BIM and CADD standards for the entire program and created the platform that the design teams used to coordinate the mechanical, plumbing, electrical, and industrial systems for facilities varying in size and complexity. Gannett Fleming also helped to establish commissioning criteria early in the planning process for multiple design teams to follow as a standard.

Key Features

  • The 12-foot by 27-foot precast wall panels are manufactured off-site to reduce weather impacts and expedite construction
  • The prototype’s kit of parts is scalable and reversible to meet specific site requirements
  • Buildings are sited with designated expansion zones to allow future bays to be easily added.

Sustainability Features & Outcomes

  • The prototype is designed to meet LEED® Silver requirements to minimize the environmental impact of new facilities across the state
  • The 10-inch-thick precast wall panels create an exterior envelope 45 percent more thermally efficient than required by code
  • Clerestory windows provide ample daylight in the maintenance bays, reducing electricity consumption.

Awards & Recognition

  • Distinguished Award, 2018, American Council of Engineering Companies of New Jersey, Engineering Excellence Awards.

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