Belt Parkway Over Ocean Parkway – Brooklyn, NY

Project Stakeholders

• Owner: The New York City Department of Transportation
• Contractor: Granite Halmar Construction Company, Inc.
• Superstructure Erector: Imperial Ironworks, Inc.
• Engineer: Gannett Fleming, Inc.

Project Overview

The Belt Parkway Bridge over Ocean Parkway in Brooklyn, NY, was a 45-year-old, two-span structure in need of full replacement. Given its high traffic volume (166,000 vehicles per day) and proximity to hospitals, schools, and businesses, traditional multi-year construction was not an option.

To ensure speed, cost-efficiency, and minimal traffic impact, the New York City Department of Transportation (NYCDOT) selected a design-build construction approach with precast bridge components to accelerate the timeline. The Granite Halmar Construction Company, Inc. (contractor) and Gannett Fleming, Inc. (engineer), in collaboration with Fort Miller Precast, delivered a high-quality bridge in a single construction season, demonstrating the power of design-build innovation.

Recognized as one of the Top 10 Bridge Projects of 2004 by Roads & Bridges Magazine, this project remains a model for high-speed, high-quality bridge replacement in New York City and beyond.

Speed: Single-Season Completion with Precast Efficiency

Using a design-build construction model, the project team cut the construction timeline from 3–4 years to just 256 days, completing the bridge 29 days ahead of schedule.

• Prefabrication at Scale: 51 precast superstructure units were pre-assembled at Fort Miller’s facility, ensuring a precise fit before arriving on-site for rapid installation.
• Seamless Construction Phases: The project followed a staged approach with a temporary bridge adjacent to the site, allowing traffic to continue flowing without detours.
• Minimal On-Site Work: Thanks to modular precast components, labor-intensive on-site assembly was reduced, keeping construction on schedule and under budget.

Traffic Mitigation: Keeping NYC Moving During Construction

Maintaining traffic flow was a top priority in this high-density corridor. The project team eliminated major traffic disruptions while replacing the bridge by adhering to design-build coordination and smart staging of precast sections.

• No Peak-Hour Lane Closures: Bridge components were installed overnight or during off-peak hours, keeping congestion at a minimum.
• Efficient Staging Plan:
  • The north half of the bridge was built first while traffic shifted onto the temporary span.
  • Once completed, traffic moved onto the new bridge, allowing the southern half to be demolished and rebuilt.
• Community Benefits: The accelerated construction timeline saved an estimated $25 million in road user delay costs, benefiting commuters, businesses, and emergency services.

Cost Savings Through Design-Build & Precast Construction

The design-build construction approach, combined with Fort Miller’s precast solutions, delivered significant cost efficiencies and long-term durability:

• Lower Project Costs:
  • The final project cost was $55.5 million, 8% below the engineer’s estimate.
  • The accelerated schedule minimized labor costs and congestion-related expenses.
• High-Performance Bridge Elements:
  • Micro silica, fly ash, and corrosion inhibitors extended the bridge’s lifespan.
  • Stainless steel reinforcement was used in the deck, barriers, and parapets, adding just 1% to project costs but doubling the structure’s service life.
• Faster, More Reliable Assembly:
  • Pre-assembled precast bridge units ensured structural continuity through loop-on-loop closure joints and post-tensioning, eliminating delays.
  • With fewer field adjustments needed, the project maintained its aggressive timeline while ensuring long-term performance.

Fort Miller Precast’s Role in Accelerated Design-Build Construction

Fort Miller’s precision-engineered precast bridge solutions were integral to the project’s speed, quality, and efficiency.

Factory-Controlled Manufacturing ensured the high-strength, 4000 psi concrete met exacting quality standards. Additionally, all 51 bridge units were pre-assembled at Fort Miller’s plant to ensure precision, preventing costly on-site issues. The pre-fabricated bridge segments were then shipped 200 miles and installed in just two weeks per half of the bridge. This limited work-zone exposure improved safety and efficiency.

A Benchmark for Design-Build Infrastructure in NYC

The Belt Parkway Bridge Replacement set a new standard for design-build construction in urban environments, proving that precast solutions and accelerated bridge construction (ABC) techniques can transform aging infrastructure faster, safer, and at a lower cost.