Toyota Roundabouts - KY 3552/I-75

SCOTT COUNTY, KY

TRANSPORTATION

Palmer Palmer Engineering partnered with the Kentucky Transportation Cabinet to develop preliminary alternatives and prepare the Interchange Justification Study for a new interchange at I-75 and KY 3552. The project was designed to relieve congestion along the US-62 corridor, improve regional mobility, and provide a new interstate access point to support the expansion of Toyota Motor Manufacturing Kentucky's facility, including the production of Lexus vehicles.

As part of the interchange improvements, Palmer designed two roundabouts on major employee and delivery access roads. Using VISSIM traffic simulations to evaluate multiple intersection configurations, the team determined that dual-lane roundabouts provided the most efficient solution for managing high traffic volumes. The roundabouts were designed to accommodate more than 2,000 vehicles exiting the facility within 30 minutes of a shift change while safely serving both passenger vehicles and large trucks. Since opening in 2016, the roundabouts have significantly reduced traffic queues and travel times while improving overall safety.

Roundabout at Toyota Motor Manufacturing in Georgetown, Kentucky

Unique Aspects

  • Opportunities

    Supporting Economic Growth: The new interchange provided critical infrastructure to support Toyota's expansion, including the addition of Lexus vehicle production, while enhancing regional economic development.

    Improving Regional Mobility: The project created a new interstate access point that relieved congestion along the US-62 corridor and improved access for employees, freight, and the surrounding community.

    Innovative Traffic Solutions: The use of VISSIM traffic simulations allowed the team to evaluate multiple intersection alternatives and implement the most efficient long-term solution.

  • Challenges

    High Traffic Demand: The roundabouts were required to accommodate more than 2,000 vehicles exiting the Toyota facility within a 30-minute shift change while maintaining safe and efficient operations.

    Complex Vehicle Mix: The design needed to safely serve both high volumes of passenger vehicles and large delivery trucks without compromising traffic flow or safety.

    Long-Term Performance: The project required a solution that improved operational efficiency while reducing maintenance needs and supporting future growth at the facility.

  • Successes

    Improved Traffic Flow: Dual-lane roundabouts replaced signalized intersections, significantly reducing traffic queues and travel times compared to preconstruction conditions.

    Enhanced Safety: The completed roundabouts reduced crashes while providing safer, more predictable traffic operations for employees and freight traffic.

    Proven Design: Since opening in 2016, the roundabouts have successfully met operational goals and are being studied as a model for similar high-volume intersections at other locations.

Key Team Members

  • Stephen Sewell, PE, PTOE

    PROJECT MANAGER

  • Will Conkin, PE, PTOE

    TEAM MEMBER

  • Gary Sharpe, PE, PLS

    TEAM MEMBER

  • Jeff Cowan, PE

    TEAM MEMBER

  • Craig Palmer, PLS

    TEAM MEMBER

  • Kelly Whittington, PLS

    TEAM MEMBER

  • Jody Barker, PLS

    TEAM MEMBER

  • Josh Coburn, PE

    TEAM MEMBER

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