Fort Miller Precast was honored to play an important role in the revolutionary application of Super-Slab® technology at Washington Dulles International Airport. This innovative approach showcases how precast concrete 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. was distinct from traditional taxiway construction because of its application of Super-Slab® technology to replace the traditional concrete slabs on the taxiway. The process not only demonstrated that Super-Slab® could be used as a suitable replacement for traditional slab concrete, but that it offered a better option because it allowed for overnight replacement of active taxiway pavement, a solution that saved both time and money.
Concrete Pavements Slabs in Airports
When they were built in the 1960s and 1970s, most airport taxiways in America were constructed using traditional concrete slabs that were around 25 feet by 75 feet in size. These slabs were reinforced with temperature steel and dowels placed across transverse joints. However, in the late 1970s, the size of these slabs decreased to 25 feet by 25 feet to try and mitigate cracking. In the decades since then, the main changes made to taxiway construction have focused on positioning dowels to further manage cracks and weathering.
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 was completed in 8.5 hours.
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, the precast concrete Super-Slabs® were intentionally warped.
Beyond that, before the slabs were placed, the subgrade was graded to the required three-dimensional surface to match the existing slabs. The use of precisely graded sub-base allowed the taxiways to be opened to aircraft traffic on un-grouted slabs. Then, the grouting was completed later during two subsequent evening closures.
Benefits of Super-Slab® Technology
Fort Miller Precast has been working on its Super-Slab® product since the company was founded 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 that we used for the Dulles Airport taxiways. As a result, Super-Slab® concrete pavement slabs provide several distinct benefits.
Minimized Disruption to Airport Operations
Because it consists of precast concrete that is manufactured offsite and transported to the place of installation, Super-Slab® offers minimal disruption in and around construction sites. This was evident in the Dulles Airport project, which was completed in a few short nights, during low-traffic times. This allowed airport operations to continue running smoothly throughout the taxiway upgrade process.
Enhanced Construction Efficiency
One of the main purposes and the largest benefits of using precast concrete, and Super-Slab® specifically, is the efficiency it offers. Fort Miller can manufacture each slab precisely, casting it to fit curved and super-elevated alignments that are specific to each location. The only onsite time needed is for installation and grouting.
Long-Term Durability and Performance
Super-Slab® is assessed by a full spectrum of testing that includes Heavy Vehicle Simulator (HVS) and FWD Load Transfer Efficiency testing. This ensures that 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 used Super-Slab® in 15 States and two Canadian Provinces on more than 100 projects with precast panels totaling over 4,500,000 square feet of installation. To put this in perspective, during this time, Fort Miller has provided more than 80% of the precast pavement installed throughout North America. Our work includes projects that range from airports to highways to bridges and beyond.
