Utilizing precast concrete pavement slabs to replace aging bus stop pads in critical transit locations.

Project Details

• Owner: New York Department of Design and Construction (DDC)
• Engineer: Gandhi Engineering
• Contractor: Gazebo Contracting
• Project Completion: 2018
• Scope: 190 8-ft x 12-ft precast concrete pavement slabs (Super-Slab®)

Project Overview

Fort Miller’s precast concrete pavement system, Super-Slab®, addressed the ongoing challenge of severe rutting at critical bus stop areas in Staten Island and Brooklyn, NY.

With the high frequency of heavy buses turning and stopping in these locations, our heavy vehicle simulator-tested solution provided the durability required to withstand these heavy loads.

To meet commuter requirements for these key transportation hubs, project contractor Gazebo Contracting elected to complete the replacements during overnight hours using Super-Slab® as a rapid precast replacement rather than traditional concrete. 

This allowed the bus stops to re-open each morning with no schedule changes for riders.

Scope and Details 

New York City Department of Design and Construction (NYCDDC) elected to “harden” 11 critical bus stop areas with a precast concrete solution. 

To eliminate rutting and improve reliability, Fort Miller supplied our Super-Slab® solution, supporting NYDDC’s mission to enhance community services with long-lasting infrastructure. 

This innovative approach prevents safety issues, such as handicap height differentials and compromised door clearances, ensuring ADA-compliant, reliable service.

Recognizing the importance of maintaining daily bus connections, Gazebo Contracting coordinated with Fort Miller for a rapid installation schedule, using strategic night work windows to keep services on track. 

The installation of each bus stop area, with configurations ranging from 7 to 30 slabs, was completed in 1 to 3 nights, meeting NYDDC’s demands for both speed and resilience in their high-traffic areas. The bus stops re-opened each morning on schedule, including during multi-night installations.

Super-Slab® is rated for a 40-year lifespan which is 2.5 times the standard for pavement. Even with the added stress of heavy equipment, NYDOT and NYDCC can expect less frequent maintenance for these key locations.

Impact and Innovation 

Through our rapid precast replacement systems, Fort Miller continues to set the standard for infrastructure upgrades, delivering precast concrete solutions that improve community accessibility and ensure long-term performance in critical transit locations.

By employing Super-Slab®, the construction team ensured a rapid turnaround on installations, significantly minimizing disruptions during critical traffic periods.