Fort Miller Precast played an important role in the revolutionary application of Super-Slab® technology at Washington Dulles International Airport. This innovative approach showcases how precast concrete pavement slabs have revolutionized overnight pavement replacement on active taxiways.
By seamlessly integrating with existing surfaces and streamlining installation processes, Super-Slab® offers a glimpse into the future of infrastructure development.
Super-Slab® at Washington Dulles International Airport
The project at Washing Dulles International Airport in Washington, D.C. stands apart from traditional taxiway construction through its application of Super-Slab® technology to replace existing concrete slabs. Super-Slab® proved not only a viable replacement for traditional slab concrete, but a superior one, enabling overnight pavement replacement on active taxiways. This solution saves both time and money.
Concrete Pavements Slabs in Airports
Most airport taxiways built in the 1960s and 1970s used traditional concrete slabs measuring approximately 25 by 75 feet. These slabs featured temperature steel reinforcement and dowels placed across transverse joints. However, in the late 1970s, the size of these slabs decreased to 25 feet by 25 feet to mitigate cracking.
Since then, taxiway construction improvements have focused on positioning dowels to further manage cracks and weathering. Over time, repeated load cycles and freeze-thaw stress cause traditional cast-in-place slabs to crack, spall at joints, and generate foreign object debris, which is a serious safety concern on active taxiways that demands rapid, reliable repair solutions.
Rapid Replacements on Taxiways Bravo and Yankee
At Washington Dulles International Airport, the 50-foot-by-50-foot area on Taxiway Bravo was replaced in two nights with eight 25-foot-by-12.5-foot-by-13-foot precast concrete Super-Slab® sections, while an additional 25-foot-by-40-foot area on Taxiway Yankee was replaced with four 20-foot-by-12.5 foot-by-13-foot thick sections in one night.
Amazingly, the entire replacement process for Taxiway Yankee finished in just 8.5 hours. With U.S. passenger airlines averaging $100.76 in operating costs per minute of aircraft block time, completing repairs within overnight windows kept those costs from compounding across daytime flight schedules.
Surface Matching and Subgrade Preparation
Because it is precast concrete, the use of Super-Slab® sped up the replacement process. Additionally, other processes connected to the use of Super-Slab® further emphasized the reasons this material was the right choice for the job. Specifically, to match the surface of the adjacent pavement, Fort Miller intentionally warped the precast concrete Super-Slabs®.
Before placement, crews graded the subgrade to the required three-dimensional surface to match the existing slabs. The precisely graded sub-base allowed the taxiways to open to aircraft traffic on un-grouted slabs immediately. To finish the project, grouting followed during two subsequent evening closures.
Benefits of Super-Slab® Technology
Fort Miller Precast has been developing its Super-Slab® product since founding the company in 2001. For more than two decades, we have refined and perfected the Super-Slab® system, which includes the same revolutionary slab-on-grade approach we used for the Dulles Airport taxiways. As a result, Super-Slab® concrete pavement slabs provide several distinct benefits.
Minimized Disruption to Airport Operations
To minimize disruption in and around the construction zone, Super-Slab® is manufactured offsite, then delivered to the installation site. This was an advantage at Dulles, where work was confined to a few low-traffic overnight windows, allowing airport operations to run smoothly throughout the upgrade.
Enhanced Construction Efficiency
One of the main purposes and the largest benefits of using precast concrete, and Super-Slab® specifically, is the exceptional efficiency it offers. Fort Miller manufactures each slab precisely, casting it to fit curved and super-elevated alignments specific to each location. The only onsite time needed is for installation and grouting.
Long-Term Durability and Performance
Fort Miller subjects Super-Slab® to a full testing regimen, including Heavy Vehicle Simulator (HVS) and FWD Load Transfer Efficiency testing. This ensures the product has the durability and performance capabilities that are necessary for every application.
Other Applications of Super-Slab®
Since its launch in 2001, Fort Miller has deployed Super-Slab® precast concrete pavement slabs across 15 states and two Canadian provinces, completing more than 100 projects with over 4,500,000 square feet installed. To put this in perspective, that means Fort Miller has provided more than 80% of all precast pavement installed throughout North America.
Beyond airports, Super-Slab® has delivered the same rapid, durable results on highways, bridges and beyond.
Learn more about the full range of Super-Slab® applications.
