1. Which toll stations are suitable for steel structure construction?
1.1 Spatial grid structure (main toll station on expressway, large hub)
- Structural advantages Bolt ball node grid is used, single span can reach 60 meters, covering 8-12 toll lanes, completely eliminating the traditional concrete column to block the field of vision, vehicle traffic efficiency increased by 25%. Material strength utilization rate reaches 90%, rods only bear axial force, adopt GB, EN, AISC design specifications, adapt to Q355B S355JR A572 SM490A high-strength steel, compressive strength 345MPa.
- Construction efficiency: The factory prefabrication rate is 95%, and the on-site assembly period is 50% shorter than that of traditional processes. The main structure of a 5,000 m2 toll station can be completed in just 60 days.
- Functional expansion integrates smart toll island (supports ETC contactless payment and license plate recognition), a photovoltaic integrated roof (annual power generation covers 30% of the station area’s electricity consumption), and a smart lighting system (light sensing to adjust brightness).
- The curved grid design can achieve a streamlined roof (such as wave-shaped or dome-shaped), and is matched with the glass curtain wall to create a transparent visual effect, which is suitable for the landmark requirements of hub-type toll stations.
- Cost reference: unit cost is $300-400 USD/㎡, and the overall cost is 20% lower than the concrete solution.
1.2 Space truss structure (scenic area/ferry special toll station, bridge, and tunnel entrance)
- Structural highlights: The box-section truss achieves a 40-meter column-free span, meeting the “unobstructed view” requirements of the scenic avenue, while being able to carry heavy equipment (such as over-limit detection equipment with a load of 5t/㎡).
- Scene adaptation, tourist attractions: special-shaped trusses shape cultural symbols (such as antique eaves, abstract forms of ethnic totems), integrating regional cultural characteristics; toll ferry: wind resistance level reaches level 12 (wind speed 32.7m/s), coastal areas are equipped with typhoon protection support system, and wind load 1.2kN/㎡ is optimized through wind tunnel test.
- Environmentally friendly steel is 100% recyclable, construction waste is reduced by 90%, and carbon emissions are 55% lower than concrete, which meets the ecological protection requirements of the scenic area.
- Cost reference: unit cost is $350-450 USD/㎡, suitable for landscape and multi-functional scenes.
1.3 Light steel structure (temporary toll booth, underground parking lot entrance and exit)
- Flexible modular detachable units can complete the construction of a 500㎡ temporary toll station within 24 hours, supporting “dismantle and relocate” to meet temporary traffic control needs for exhibitions, events, etc.
- The intelligent configuration integrates mobile toll booths (including weighing systems and ticket printing), lifting barriers, and remote monitoring cameras. Only two people are needed to man a single station, reducing labor costs by 60%.
- Cost reference: $80,000-120,000 USD per module, suitable for short-term needs or emergency scenarios.
2. Why are steel structure toll stations the preferred choice at global transportation hubs?
2.1 Rapid construction to seize the first opportunity of opening to traffic
- Factory prefabrication + on-site assembly mode: The main structure of the 10,000 m2 toll station was completed in 90 days, 180 days shorter than the concrete solution, which is more advantageous in meeting short-term construction needs.
- Modular expansion: Reserved interfaces support “expansion while operating”, and new lanes can be connected within 7 days without interrupting traffic.
2.2 Flexible layout, adaptable to multiple scenarios
- Large column-free space: The 60-meter span grid realizes a “fully open toll plaza”, which can dynamically adjust lane functions (such as tidal lanes and new energy dedicated lanes), and the space utilization rate is increased by 30%.
- Intelligent partitioning: The office area, equipment room, and convenience service points can be quickly divided through removable partition walls to meet the complex functional requirements of “collection + tourist consultation” at scenic spot toll stations.
2.3 Green and sustainable, responding to the “dual carbon” goals
- Photovoltaic integrated system: The annual power generation of the roof photovoltaic panels can reach 500,000 kWh, covering the lighting of the station area, equipment electricity, and surrounding road lighting, with an overall energy saving rate of 40%.
- Circular materials: 90% of components are reusable, the recycling rate of retired steel is 100%, and the carbon footprint of the entire life cycle is 63% lower than that of concrete.
2.4 Safe and intelligent, ensuring efficient operation
- Earthquake and wind resistance: Earthquake resistance is level 8, and typhoon-proof cables are standard in coastal areas, which can withstand level 14 strong winds (wind speed 42.5m/s).
- Smart management: Integrated AI video analysis (traffic flow monitoring, congestion warning) and equipment remote operation and maintenance system, shortening fault response time from 2 hours to 15 minutes.
3. Application scenario matrix of steel structure toll station
| Scene Type | Technical Solution | Core Performance | Cost reference |
| Main highway toll station | 60m space grid + intelligent charging island | Average daily traffic volume: 50,000+ vehicles, supporting 12 lanes of parallel operation | $350-450 USD/㎡ |
| Scenic spot toll station | Special-shaped truss + cultural theme modeling | Wind resistance level 10, integrated with natural landscape design | $450-600 USD/㎡ |
| Toll Ferry/ Bridge | Wind-resistant trusses + corrosion-resistant coating | Salt spray corrosion resistance (coastal areas), load 8t/㎡ | $400-500 USD/㎡ |
| Temporary traffic control point | Modular light steel structure + mobile equipment | Deployment completed in 48 hours, single module covers 2 lanes | Single module $80,000 |
| Underground parking entrance | Steel structure frame + translucent ceiling | Clearance height 5 meters, equipped with an intelligent height limit warning | $320-400 USD/㎡ |
4. Steel structure vs. traditional concrete: In-depth comparison of toll station scenarios
| Core indicators | Steel structure scheme | Traditional concrete solution |
| Maximum single span | 60 meters of column-free space | ≤20 meters (need dense columns) |
| 10,000㎡Construction period | 90 days | 360 days (including maintenance) |
| Lane adjustment flexibility | Modular partition wall renovation completed in 3 hours | It will take 7 days to demolish the wall, affecting traffic |
| Carbon emissions | 1.0tCO₂/㎡ (67% reduction) | 3.0tCO₂/㎡ |
| Renovation cost | Replacement of partial components reduces costs by 80% | Structural demolition generates 500 tons of construction waste |
| Earthquake resistance | Level 8 | Level 6-7, high-intensity areas need reinforcement |
5. Key Components and Technical Standards
5.1 Load-bearing system
- Steel columns: Made of Q355B S355JR A572 SM490A high-strength steel, with a column spacing of 12 meters to reduce the interference of columns on the lane line of sight.
- Space grid: bolt ball node, maximum span 60 meters, stress distribution of rods optimized through 3D modeling, wind load tolerance 1.0kN/㎡.
- Wind-resistant support: Coastal projects are equipped with oblique steel cables as standard, which can withstand typhoon-level horizontal loads.
5.2 Enclosure and intelligent system
- Photovoltaic ceiling: double-layer corrugated steel plate + photovoltaic glass, with a light transmittance of 30%, combining power generation and sunshade functions.
- Smart toll island: integrated with ETC antenna, license plate recognition camera, and voice interactive screen, the single-vehicle travel time is shortened to 8 seconds.
- Noise barrier: light steel keel + 100mm rock wool sandwich panel, sound insulation reaches 55dB, reducing the impact of passing vehicle noise on the station area.
6. Frequently Asked Questions
Q1: Can steel structure toll booths withstand the load of heavy trucks?
A: Fully satisfied. XTD Steel Structure uses super-heavy-duty H-shaped steel trusses, and the ground load design can reach 15kN/㎡ (equivalent to a single lane carrying a 50-ton truck), which has passed ANSYS structural mechanics calculations and on-site load tests. For example, at a high-speed overload inspection station, a single lane successfully carried an 80-ton large transport vehicle, and the rod stress was controlled within 60% of the steel yield strength to ensure structural safety redundancy.
| Performance Indicators | Steel structure toll booth | Traditional concrete toll booth |
| Design value of ground load | 15kN/㎡ (single lane carrying 50 tons of truck) | Usually ≤10kN/㎡ (additional reinforcement required) |
| Single lane carrying capacity | The vehicle was tested to carry 80 tons of heavy goods. | Generally, you can only carry vehicles below 30 tons |
| Verification Method | Through ANSYS structural mechanics calculation and on-site load testing | Lack of dedicated testing for high-load scenarios |
| Actual test cases | A single lane of a high-speed overload inspection station can carry 80 tons | No similar high-load measurement records |
| Stress Control | The stress of the rod is controlled within 60% of the yield strength of the steel | Concrete cracking and steel corrosion risks are likely to occur under high loads |
Advantages: Steel structures can absorb seismic energy through a flexible frame + core tube system. For example, a coastal toll station uses “tuned mass damper” technology to control wind vibration displacement within 50mm, while traditional concrete needs to rely on thick walls, resulting in a 20% reduction in space utilization.
Q2: How long can the construction period of a steel structure toll station be shortened compared to traditional concrete?
A: The construction period is shortened by more than 50%. Taking the main toll station of a 10,000 square meter highway as an example, the main steel structure adopts the “factory prefabrication + on-site assembly” mode and can be completed in 90 days, while the traditional concrete solution requires 360 days (including maintenance). The modular design supports “operation and expansion at the same time”, and the new lanes can be connected within 7 days without affecting normal traffic.
| Construction Phase | Steel structure scheme | Traditional concrete solution |
| 10,000㎡ Main structure construction period | 90 days (including on-site assembly) | 360 days (including concrete curing) |
| New lane expansion cycle | 7 days (modular interface, no interruption of traffic) | 30 days (need to demolish and rebuild, affecting traffic) |
| Component processing method | Factory prefabrication rate 95%, accuracy ±2mm | Casting on site requires a formwork/dismantling process |
Key points for improving efficiency: Steel structure components are welded and anti-corrosion treated in the factory, and only bolt connections are required on-site, reducing on-site operations by 70%. For example, a toll station in a scenic spot took only 120 days from design to delivery, and was put into use 240 days earlier than the concrete solution.
Q3: How much lower is the life cycle cost of a steel structure toll station than traditional concrete?
A: The life cycle cost is lower. Although the unit cost of steel structure is about $300-450 USD/㎡, which is slightly higher than the initial investment of concrete, the shortened construction period saves 40% of management fees and financing costs, and the later transformation costs are reduced by 80% (only partial component adjustments are required). Calculated over 20 years, the comprehensive cost of steel structure is 15%-20% lower than that of concrete, and steel is 100% recyclable, with a residual value rate of 25%.
| Cost Type | Steel structure scheme | Traditional concrete solution |
| Unilateral cost | $300-450 USD/㎡ | $280-400 USD/㎡ |
| 20-year maintenance costs | The annual average cost is 3%-5% of the initial construction cost (anti-corrosion/testing) | The annual average cost is 5%-8% of the initial construction cost (wall repair/waterproofing) |
| Renovation cost | Replacement of partial components reduces costs by 80% | The demolition of the structure generated 500 tons of construction waste, which was costly. |
| Residual value recovery | Steel is 100% recyclable, with a residual value of 25% | The residual value of concrete is less than 5% |
Q4: How is the environmental performance of the steel structure toll station reflected? How big is the difference from traditional concrete?
A: Through the triple environmental protection system: ① Material recycling: 90% of the components can be reused, the recycling rate of retired steel is 100%, and the construction waste is reduced by 90%; ② Low-carbon construction: carbon emissions are only 1.0tCO₂/㎡, which is 67% lower than concrete; ③ Energy saving: standard photovoltaic integrated roof (annual power generation covers 30% of the station area electricity) + ground source heat pump, the comprehensive energy saving rate reaches 40%, which meets the green building standards.
| Environmental indicators | Steel structure toll booth | Traditional concrete toll booth |
| Carbon emissions | 1.0tCO₂/㎡ (67% reduction compared to concrete) | 3.0tCO₂/㎡ |
| Construction waste | 90% reduction (modular construction, no on-site wet work) | 500-800 tons of construction waste/10,000 m2 |
| Material recovery rate | 90% of components are reusable, and steel is 100% recycled | Only steel bars can be partially recycled, with a recycling rate of <20% |
| Energy efficiency | Photovoltaic roof generates 500,000 kWh of electricity per year, saving 40% of energy | No active energy-saving facilities, high energy consumption |
Typical case: A steel structure toll station in a scenic spot adopts “photovoltaic integrated roof + ground source heat pump”, which reduces carbon emissions by 280 tons per year, equivalent to planting 15,000 fir trees. The traditional concrete solution requires an additional investment of $300,000 to install soundproof walls and air conditioners, and cannot achieve carbon emissions reduction.
Q5: Can the appearance of toll stations in special scenes, such as scenic spots/ferry crossings, be customized?
A: A highly customized design is supported. Through BIM digital modeling and special-shaped truss technology, cultural theme shapes (such as antique eaves, ethnic totems), streamlined curved roofs (such as wavy domes) can be achieved, with glass curtain walls or wood grain transfer steel plates. For example, a toll station in a 5A scenic spot uses “bamboo slips” as the design language, uses gradient color steel plates to simulate bamboo textures, takes into account landscape integration and modernity, and has a wind resistance level of 10.
| Design Dimensions | Steel structure scheme | Traditional concrete solution |
| Maximum single span | 60 meters of column-free space (covering 12 lanes) | ≤20 meters (need to have dense columns to block the line of sight) |
| Modeling plasticity | Supports curved domes, antique shapes, and hollow carvings | Only a straight roof can be achieved, with a single shape |
| Function adjustment speed | Modular partition wall completes driveway transformation in 3 hours | It takes 7 days to demolish the wall, affecting operations |
| Landscape integration | Customizable wood grain steel plate, glass curtain wall, and other finishes | Relying on paint or external stone, high cost |
Application example: A coastal ferry toll station uses wind-resistant trusses + wave-like curved roofs, and uses BIM technology to achieve 1:1 digital pre-assembly with a modeling error of less than 3mm. Traditional concrete requires customized complex formwork, which extends the construction period by 45 days and makes it impossible to realize the curved light-transmitting skylight design.
XTD Steel Structure: Transportation Infrastructure Innovator
With the experience of constructing 30+ large-scale steel structure buildings, we have injected the concept of “ultra-fast construction, intelligent integration, and green sustainability” into the construction of toll stations. So far, we have delivered 20+ transportation hub projects, helping customers to create a new generation of toll station benchmarks with “zero waiting time, zero carbon emission station area, and zero visual obstruction”.