The T-WALL retaining wall shown is located between E. Ann Street and E. Allegheny Avenue on the Delaware River side of I-95. The 3-D wave pattern with ghost waves was designed by PennDOT and created with custom formliners from Architectural Polymers. The design concept is to commemorate the history between the citizens of Philadelphia and the Delaware River.

As one of seven covered bridges in the Lehigh Valley, Schlicher's Bridge spans the Jordan Creek at 116 feet in length. Surrounded by the Game Preserve, it is commonly referred to as the "deer pen bridge" where deer are often seen grazing.

The 1.5 mile Nimmo Parkway connector project aimed to improve traffic congestion connects the Nimmo Parkway with Holland Road and General Booth. The designs selected by the VDOT depict the seashore, farmland, mountain and other signature Virginia landscapes.

The $28 million Princess Anne Road project widened the road to a four-lane roadway. The VDOT specified a brick and mortar design to complement the nearby VA Beach Municipal Center.

Sound barrier walls were critical for both projects to protect the neighboring Virginia Beach residents from the anticipated increased traffic noise.

Working with an Aesthetics Subcommittee representing key stakeholders in Council Bluffs and the State of Iowa, HDR created the design for the precast concrete walls featuring a simple rolling hill theme reflecting the Loess Hills. The contractor, Hawkins Construction Company, worked with precaster American Concrete Products to further develop the design. Utilizing custom elastomeric formliners from Architectural Polymers, the rolling hill design featured five different textures including Medium Sand Finish, Bush Hammered, Fractured Stone, Tree Bark and M&R Modified. The combined effect of both texture and color ensures the design is easily recognizable from all viewing angles, including that of the driver.

The Ohio State University and Athens city officials teamed up with contractors, designers and the Ohio Department of Transportation to redesign the historic bridge. Local architecture firm Panich and Noel designed two custom murals on the abutments beneath the bridge. The first mural represents the Marietta to Cincinnati Railroad. The second shows the Hocking River, wildlife, the original bridge (from 1870) and the Athens Asylum. The contractor, Shelly and Sands worked with Architectural Polymers to create the custom formliner.

The Jim Thorpe Memorial Bridge over the Lehigh River was originally constructed in 1953 and rehabilitated in 1976. After being ruled structurally deficient, plans began for a replacement. The new bridge, currently under construction, will be twice as wide as the existing bridge, to handle the increased traffic averaging over 9,500 vehicles per day. The new bridge will be named for Sgt. Andrew J. Baddick, a Jim Thorpe soldier killed in Iraq, who grew up along the Lehigh River and served as a river guide before joining the military.

The PATPC bridge over Pohopoco Creek construction project is part of the Pennsylvania Turnpike Commission’s plan to rebuild and modernize more than 600 miles of interstate highway and mainline structures. Originally constructed in 1957, the existing bridge carries an average of 30,000 vehicles per day. The new bridge, being constructed within 20 feet of the existing bridge, will include two lanes in each direction and two shoulders. The general contractor, Walsh Construction, designed the new bridge to be in harmony with the Pocono Mountains’ environment. This precast concrete alternative saved the Pennsylvania Turnpike Commission a few million dollars over the original steel girder design.

The Freemansburg Avenue bridge over PA 33 will increase from five lanes to eight lanes, including some turning lanes and widened ramps. The widening project will help the area prepare for the construction of 837 new homes and 140,000 square feet of commercial space as well as a new St. Luke’s Anderson campus.

Architectural Polymers used CAD/CAM systems to transform sound barrier walls into concrete art. They started with a rough design concept and created a simple 2D sketch. Using CAD (Computer Aided Design) software, they turned the 2D sketch into a 3D rendering. Upon approval of the 3D rendering, they applied CAD/CAM technology to translate the model into numerical code to be processed by a 3D CNC (Computer Numeric Control) machine. The CNC, an automated computer-controlled 3D router, then created the design in the architectural formliner.

Showcasing the orange and orange blossom, which are representative of Florida, the sound barrier walls became more than just a functional component of the project.

Butte des Morts Causeway Opening

Big Lake Butte des Morts is an 8,800-acre (36 km2) lake located in Wisconsin and is part of the Winnebago Pool (also known as the Winnebago System). Originally opened in 1955, the Lake Butte des Morts Causeway recently received an upgrade. To better accommodate increasing traffic volumes on highway 41, WisDOT built a new, eight-lane crossing created by widening the existing structure to the west. The new causeway will provide increased safety and stability.

The Lake Butte des Morts Causeway was identified as an opportunity to celebrate the culture and history of the state's diverse Native American tribes. WisDOT received input from the eleven federally recognized Native American tribes of Wisconsin. Custom produced architectural formliners from Architectural Polymers were used on the parapets, abutments and piers to help identify this diversity. See Website photos.

Architectural stain was used to enhance the custom graphics.

The Causeway opened in June on time and under budget.

Architectural Polymers® employed its custom mold manufacturing skills to give the arriving tourists a fresh view of the lesser known identity of Sanibel Island. 3D Graphics were generated and carved by CadCam process.

Staining was added as a final effect to enhance the subject matter.

A majority of the 275,000 square foot facility’s exterior facade on the east, west and south exposures features a pre-insulated, custom-designed precast concrete wall system. The precaster, Gate Precast worked with Beck Architecture to develop the precast concrete wall system. The design features a basket weave pattern in light buff with a medium sandblast finish created with custom elastomeric formliners by Architectural Polymers. The thermally-resistive precast concrete material is not only cost-effective and aesthetically pleasing; it provides an energy efficient solution that protects the structure from the harsh Texas sun.

Visit Architectural Polymers at the 2014 PCI Convention at Booth #312.

The new $345 million Mercy Joplin Hospital features precast concrete exterior cladding, concrete roofs with hurricane-grade penthouses and high-impact glass secured by the precast concrete. The precaster, Enterprise Precast Concrete, Inc., used Versa-Brix® M from Architectural Polymers to create the strong visual facade that offered the necessary levels of storm resistance.

LMN Architects designed the Global Center to complement the historic context and surrounding area while highlighting the contemporary high-tech marketplace. They selected precast concrete for the exterior facade not only for its custom design capabilities, but also for its speed in manufacturing and installation. LMN worked closely with the precaster, Sidley Precast, to develop a facade that mimics the tone of limestone while offering fine details that would appear in various lighting conditions. Utilizing custom formliners from Architectural Polymers, the design is noted to resemble the twisting helices of a DNA molecule.

The Global Center for Health Innovation occupies 235,000 square feet adjacent to the Cleveland Convention Center with four floors featuring distinct medical themes. Each floor includes space that is rented by major medical manufactures. The first floor is the Patient Home floor where University Hospital, Cleveland Clinic and MetroHealth showcase current technologies for patient safety at home. The second floor is dedicated to People, Patients and Caregivers with GE Healthcare, Cardinal Health and Cisco. The third floor features Phillips Healthcare and Siemens with a focus on devices and technologies that enhance the clinical experience. The fourth floor is occupied by health IT group HIMSS who plans to use it as an interoperability testing center.

As both tenants plan to remain in the building for a long time, the materials selected and long-term lifecycle costs were a key concern. Precast concrete quickly became an obvious choice not only for its durability but also because it offered a cost-effective and energy-efficient solution.

Polsinelli Headquarters and Hotel Sorella

The precaster, Enterprise Precast, used a custom Italian-style formliner from Architectural Polymers to create the light white, acid-etched concrete facade. The liner was used with 6" panels and features an intricate infill pattern.