Fort Miller’s Super-Slab® system helped NYSDOT accelerate interstate rehabilitation on I-95 by installing precast concrete pavement panels on the Alexander Hamilton Bridge approaches within tight overnight work windows.

Project Details

• Owner: New York State Department of Transportation (NYSDOT)
• Engineer: NYSDOT
• Contractor: CCA/Halmar Incorporated
• Completion Date: 2013
• Scope: 425 Super-Slab® precast concrete pavement panels  

Project Overview

The Alexander Hamilton Bridge carries 8 lanes of nonstop I-95 traffic between Manhattan and the Bronx, linking the Cross Bronx Expressway with I-87 via a maze of ramps. Severely deteriorated approaches dated back to the early 1960s, requiring modernization and upgrades to meet current standards.

NYSDOT sought an accelerated replacement strategy that could work inside a five-hour overnight window, as every closure decision results in delays and safety risks for the 200,000+ vehicles traveling the corridor. 

Additionally, the approach geometry included horizontal and vertical curves, variable lane widths, and transitions that demanded tight tolerances and custom panelization. Fort Miller provided Super-Slab® precast concrete pavement panels, designed for rapid installation, precise fit, and fast reopening.

Scope and Details

Because lane access was limited and closure time was short, the entire delivery had to support repeatable nightly production. 

Fort Miller supplied over 425 Super-Slab® precast concrete pavement panels, a slab-on-grade system allowing for rapid overnight replacement of the deteriorated approach pavement.

Panels were fabricated with stainless steel reinforcing bars and load-transfer dowels to hold up to heavy interstate traffic and harsh deicing conditions. Each precast slab was cast to match the required thickness, crown, and superelevation of the roadway, allowing even complex vertical curves or warped surfaces to be handled by custom panel shapes.

The precast concrete pavement panels were installed during tightly constrained nighttime work windows when traffic volumes were lowest. In the most critical areas, the contractor was typically granted a single lane closure for a 5-hour window to remove and replace that lane’s pavement. Even under those constraints, the contractor was frequently able to install up to 10 panels per shift.

Impact and Innovation

This project is a clear example of why precast concrete pavement panels matter on high-volume corridors. Super-Slab® panels allowed for rapid installation during narrow overnight work windows, even with complex geometry. Field crews set panels quickly, kept lines and grades true, and avoided the delays that come with extensive hand-finishing or on-site adjustments.

The result was an accelerated replacement strategy that delivered speed when it was needed and performance built to last.