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State & Local Government Projects

Secaucus Maintenance Facility

Owner: New Jersey Turnpike Authority
Location: Secaucus, N.J.

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overhaul, NJTA hired Gannett Fleming to conduct a statewide assessment and develop a prototype design to replace 15 outdated facilities.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 provide 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.

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. 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.