Architectural Polymers

Versa-Brix® 3D Thin Brick Formliner for Historic Precast Restoration

The rehabilitation of the Baltimore Harbor Tunnel (I-895) ventilation buildings demonstrates how innovative concrete forming technology can preserve historic architecture while meeting the demands of modern infrastructure. Originally constructed in 1957, the north and south ventilation buildings are vital for tunnel safety. They continuously remove vehicle emissions and supply fresh air to one of Maryland's busiest transportation routes, serving over 27 million vehicles each year.

As part of the Maryland Transportation Authority's multi-year modernization program, the aging building exteriors were replaced with architectural precast concrete panels manufactured by Smith-Midland Corporation. Collaborating with JMT Architecture, Carroll Engineering, and general contractor W.M. Schlosser Company, the project team developed a phased renovation plan that allowed the ventilation facilities to remain fully operational throughout construction.

Architectural Polymers provided its Versa-Brix® 3D thin brick form liner system, creating the dimensional brick façade that preserves the buildings' historic appearance while offering the durability and efficiency of architectural precast concrete. The project represents a notable advancement in Versa-Brix® 3D technology, utilizing primarily plastic form liners with strategically placed rubber overlay pieces. This carefully crafted design achieves the varying brick depths that give Versa-Brix® 3D its distinctive shadow lines and authentic masonry character. Successfully leveraging plastic form liners into this complex application demonstrates the versatility of the Versa-Brix® system while offering production efficiencies for large architectural precast projects.

The Baltimore Harbor Tunnel project illustrates how advanced thin brick form liners, architectural precast concrete, and innovative manufacturing techniques can successfully restore historically significant infrastructure while improving durability, constructability, and long-term performance.