Alcoa Lancaster Works Improvements

Home to Alcoa since the late 1940s, the Lancaster Works plant is a leader in aluminum production, specializing in a wide assortment of aluminum sheet and cast plate products. Alcoa is committed to continually upgrading and making modifications at its 1.3 million-SF plant, which gives them a tremendous advantage in producing quality products for their customers. RETTEW has a long-standing relationship with Alcoa, so when production increased at the plants, we were there to help with various improvements and maximize the use of their 107-acre site.

One improvement project was expansion of the rail yard to accommodate drop-off deliveries from Norfolk Southern. Along with realigning rail spurs, grading and layout plans, as well as circulation plans, we coordinated approvals through the Lancaster County Conservation District, Manheim Township, PPL Utilities, and Norfolk Southern. RETTEW also worked with Alcoa to expand the storage yard at one of several working plants on site. Because of our understanding of the local permitting process, we collaborated with Manheim Township to consider this a maintenance project, which did not require Township approval. A third project was improvements around the existing truck scale area, including increased circulation, parking, and stormwater improvements that aligned with their stormwater master plan. We realigned the truck access drive so trucks could avoid the on-site hazardous material storage building, and we expanded the stoned truck holding area. Some project challenges included various utility crossings and working around trucks that were loading, unloading, and maneuvering throughout the site. In the end, these projects successfully increased Lancaster Works’ efficiency and maximized their land use.


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