Our paving solution for replacing structurally deficient concrete pavement on I-78 ramps over Routes 1 and 9 in Newark, New Jersey.

Project Details

• Owner: New Jersey Department of Transportation (NJDOT)
• Engineer: TY Lin
• Contractor: Union Paving
• Project Completion: 2018
• Scope: 400 Super-Slab® precast units 

Project Overview

This project initiative targeted aging and structurally deficient concrete pavement and driving surfaces that form part of the I-78 Interchange 58 in Newark, New Jersey. Given the project’s proximity to major transport hubs, minimizing disruption was a key consideration.

Fort Miller’s Super-Slab® paving system provided a rapid, efficient solution that kept traffic flowing smoothly during construction.

Designed for quick and easy installation, Super-Slab® allows DOTs to replace concrete riding surfaces with little downtime and during limited closure windows, dramatically reducing the impact on traffic.

Fort Miller provided 400 Super-Slab® precast units, with the project completed in stages overnight and on weekends to minimize the impact on traffic, marine terminal traffic, and airline travel.

Scope and Details 

The contractor used precast and cast-in-place components to tackle the project’s complex geometry (including varying lane widths, intricate curves, and cross slopes) on the ramps. The Super-Slab® system facilitated fast, precise replacements, allowing the team to meet stringent deadlines and specifications. Key execution strategies included:

• Efficient Installation: The team easily installed up to 100 slabs during the limited 55-hour weekend closures, demonstrating the paving solution’s efficiency.
• Precision Engineering: The team used a D-3 dozer, controlled by a robotic total station, to precisely shape the base material into the required 3-D geometry with +/- 1/8 inch accuracy required for the project.

Impact and Innovation 

The I-78 project is a testament to the synergy between innovation and functionality, representing a significant advancement in paving solutions. 

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

The precise and rapid installation of the slabs also meant that traffic could resume sooner than with traditional methods, ensuring that disruptions to both local commuters and critical logistic operations were kept to a minimum. 

This method proved crucial for maintaining smooth traffic flow in a busy urban corridor, including access to Newark Liberty International Airport and Port Newark.

Additionally, using precast slabs means less frequent maintenance for NJDOT.