Gowanus Expressway Viaduct

Champion Specialty Services played a critical role in the New York State Department of Transportation’s multi-year rehabilitation of the Gowanus Expressway Viaduct in Brooklyn, NY. Under subcontract to El Sol Contracting, Champion was tasked with blasting and repainting a massive 5 million square feet of elevated roadway steel, spanning over 4 miles of structure, while performing all work above or adjacent to live traffic in one of the nation’s most congested corridors.

Scope of Work

Champion’s scope included a complete surface preparation and multi-coat protective painting system for the viaduct steel:

• Surface Prep: SSPC-SP 10 (Near-White Metal Blast Cleaning)
• Coating System: Sherwin-Williams 3-coat zinc/epoxy/urethane system
• Quantity: Over 5 million square feet of steel
• Access System: Installed and maintained 1 million square feet of SafeSpan platform for worker and equipment access, leapfrogging the system along the structure as work progressed.
• Rapid Deployment Operations: Approximately 200,000 square feet completed under accelerated conditions to address low-clearance areas.
• Traffic Conditions: All work executed over and adjacent to active traffic lanes, requiring precise safety planning and coordination.

Execution Strategy

The Gowanus Expressway project required balancing technical precision, productivity, and safety compliance under highly complex urban conditions. Champion Specialty Services utilized a segmented leapfrogging approach, installing SafeSpan platforms in sequential sections to minimize downtime and accelerate the schedule. Specialized crews and equipment were mobilized to address tight-clearance areas without disrupting mainline operations. At the same time, comprehensive traffic control and containment plans ensured debris control, environmental compliance, and uninterrupted commuter traffic beneath the viaduct.

Project Challenges

Delivering this project in one of New York City’s busiest transportation corridors presented significant challenges. Urban congestion demanded constant coordination with NYSDOT, the general contractor, and traffic control teams to maintain productivity. Strict environmental and safety protocols were required to manage lead-based paint removal and protect worker safety. Adding further complexity, the project faced high schedule pressure, with aggressive daily productivity targets necessary to not only meet but ultimately accelerate the completion timeline by six months.

Results & Achievements

Champion’s disciplined execution produced outstanding results. The base scope was substantially completed in April 2025—six months ahead of the contractual deadline. Quality excellence was achieved with NYSDOT granting first-pass acceptance on most work sections. Operationally, Champion leapfrogged more than 1 million square feet of SafeSpan platform without schedule disruption, while maintaining a flawless safety record with no lost-time incidents. Due to this exceptional performance, Champion was awarded additional unit price work, further expanding its role on the project.

Key Takeaways

The Gowanus Expressway Viaduct project highlighted Champion’s ability to deliver large-scale, high-complexity infrastructure rehabilitation under some of the most demanding urban conditions. Through innovative access strategies, disciplined project controls, and a safety-first culture, Champion not only delivered a high-quality outcome but also outperformed schedule and safety expectations. This success reinforces Champion’s reputation as a trusted partner for major transportation infrastructure projects.