08.03.2014 START OF WORKS • 02.06.2014 - 6.10 am FIRST TAKE OFF AT THE END OF WORK

New LED lightingon the entire runway

400 kmwiring

Vitali

Special customasphalt

Planning and organisation Men and machines

Phase 3:runway

Phase 2:runway end safety area 28

Phase 1: runway end safety area 10

Meeting the strict schedule in 3 phases

The challenge demand and figures

The Orio al Serio airport

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28

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16

12

8

6

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International Orio al Serio

airport.A ONE-OF-A-KIND

operation.

The Orio al Serio airport, near Bergamo, is the fourth largest

Italian airport in terms of passenger transit and the leading

cargo airport. Strategically located in the heart of Lombardy,

less than 40 kilometres from the city of Milan, in just a few

years it has reached peerless operating levels for this type of

location. The impressive business growth naturally strained all

the infrastructures, starting with the “wear” and maintenance

conditions of the single take-off and landing runway. Logistic

airport growth, still in progress and that will require Orio al

Serio to adjust to even more demanding challenges, focused

its growth strategies on runway adjustment to improve user

services in terms of efficiency and safety.

Firstin Europefor cargo

Fourthin Italy for passenger

transit

The Orio al Serioairport

2 3

“A one-of-a-kind operation. Demanding from every

standpoint: never before, indeed, had such radical

runway and taxiway work been successful on such

a significant airport, reducing downtime to less than

three weeks”. The purchaser’s words, expressed by

Andrea Mentasti, Sacbo general manager, revealed

the complexity of the work commissioned to the

Vitali team. Yet the goal that seemed practically

impossible was not only reached, but work was

completed a day earlier than originally scheduled,

avoiding every and all “non-conformities”.

The challengedemand and figures

Sacbo invested a total of 50 million Euro for this work which,

in addition to flight infrastructure work, included runway light

control systems as well as plumbing and IT updates.

The key “figures” that characterised Orio al Serio airport

infrastructure renovations clearly express the extent and

complexity of the job:

• Overall paved area subject to work: 550,000 square

metres (corresponding to 80 football fields)

• Total new asphalt to be poured: 220,000 tonnes

(corresponding to about 6,500 35.5 t lorries).

• Required horizontal markings: over 70,000 square

metres (corresponding to 10 football fields).

• About 400 km of electric wires laid.

• Installation of over 2,000 new flight navigation

assistance lights with LED technology.

500,000square metrepavement area

200,000 tnew asphalt

400 kmwiring

2,000 LEDAVL lights

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Work on flight infrastructures and other

intervention elements at the Orio al Serio airport

fully met the strict schedule set by the purchaser.

The first two phases were scheduled from March

8th to May 12th, first on runway end safety area

10 (West) and then on runway end safety area 28

(East) with any interruption or limitation to fight

activities. The purpose of the third and last phase,

from May 13th to June 1st, was to complete

renovations and repave the entire runway, links

and taxiways.

Monday, June 2, 2014, at 6 AM, the International

Orio al Serio airport runway was reopened

for work, fully meeting the set schedule. The

infrastructure was practically completed one day

early.

Meeting the strict schedule in 3 phases 08.03.2014 - 25.04.2014

26.04.2014 - 12.05.2014

13.05.2014 - 01.06.2014

PHASEONE

RUNWAY END SAFETY AREA 10

Airport open

Airport closed

Airport open

PHASETWO

RUNWAY END SAFETY AREA 28

THE RUNWAY

PHASETHREE

Beforeschedule

6 7

RUNWAY END SAFETY AREA 10

PHAS

EON

E08

.03.

2014

- 25

.04.

2014

RUNW

AY E

ND S

AFET

Y AR

EA 1

0

Pavement renovation and asphalt poured on a 90,000 square metre area

Installation of 410 new LED lights on the runway

Creation of new 5,000 square metre concrete aircraft hangar lot

Levelling and load capacity increase of a 13,500 square metresafety grass area located at the end of the runway

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DEPARTURE / ARRIVALS

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4

RUNWAY END SAFETY AREA 10

10 11

PHAS

ETW

O26

.04.

2014

- 12

.05.

2014

75 80

DEPARTURE / ARRIVALS

Pavement renovation and asphalt poured on a 50,000 square metre

area

Installation of280 new LED lightson the runway

Creation of new

5,000 square metre concrete aircraft hangar lot

Levelling and load capacity increase of 8,000 square metressafety grass area at the end of the runway

RUNWAY END SAFETY AREA 28

RUNW

AY E

ND S

AFET

Y AR

EA 2

8

12

1514

RUNWAY END SAFETY AREA 28

THE RUNWAY

PH

AS

ET

HR

EE

13.0

5.20

14 -

01.

06.2

014

THE

RU

NW

AY

Pavement renovation and asphalt poured on a 295,000 square metre area

6 construction sites simultaneously running, each per shift with dedicated foreman, team and equipment

4 m of asphalt per minute

800 lorries per day

Installation of 1,800new LED lights on the runway

Demolition of the C link

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08.03.2014 START OF WORKS

1 2

3

02.06.2014 - 6.10 am FIRST TAKE OFF AT THE END OF WORK

3

h00.00 h05.00 h10.00h01.00 h06.00 h11.00h02.00 h07.00h03.00 h08.00h04.00 h09.00

7 days a week

h12.00 h18.00h13.00 h19.00h14.00 h20.00h15.00 h21.00h16.00 h22.00h17.00 h23.00

24 hours a day

WORK SITE 3

WORK SITE 4WORK SITE 6WORK SITE 5

WORK SITE 2

WORK SITE 1 RUNWAY END SAFETY AREA 28RUNWAY END SAFETY AREA 10

Challenges are met with numbers

In the third phase 6 worksites open simultaneously

and perfectly coordinated

One foremanOne team Dedicated vehicles for each site, on 3 shifts

A carousel of vehicles of every shape and kind, continuously moving 24/7. The work plan

included 300 workers per shift, 600 latest generation vehicles equipped with GPS systems

to maintain project benchmarks.

The milling and laying phase that concerned an overall surface of over 300,000 square

metres included some of the most innovative machines on the world market with

exceptional performance.

900 workers

600 latest generation

vehicles

800 lorries per day

4 mt asphalt

per minute

To meet job expectations and the strict schedule, Vitali and its partners put an

exceptional work team into place, both on the human resource level and concerning

the vehicle fleet and machinery.

Technologies were adequately coordinated in use to

optimise work time, results and costs.

THE RUNWAY

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Planning andorganisationMen and machines

900 workers were involved divided into 3 shifts.

7 days a week, 24 hours a day. Over 600

latest generation vehicles with GPS systems to

maintain project benchmarks. Regarding the

sub-foundation phase, GRADERS and DOZERS

also equipped with GPS were used. The milling

and laying phase concerned a total surface

over 550,000 square metres using some of the

most innovative machines on the world market

such as the BOMAG BF800 finishing machines,

WIRTGEN W210 mills and WR 2000 stabilisers

with exceptional performance in addition

to rollers, mechanical shovels, excavators,

telescopic lifters, etc.

2 cement mixers and sieves were placed on site

to crush excavation scrap material.

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600 latestgenerationvehicles

GPStechnology on

all vehicles

900 workers

on 3 shifts

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Special custom asphalt

To ensure the maximum reliability and durability

of the new Orio al Serio runway asphalt strip,

Vitali engineering designed and created a

special bitumen composite using HARD

bitumen and fibres with exceptional technical-

functional properties meeting ENAC and ICAO

technical-regulatory requirements. The strip is 30

centimetres thick.

The modified bitumen provides the asphalt with

both higher elasticity and greater resistance. To

ensure work accuracy, asphalt was laid with the

hot joint method on the entire runway.

200,000tonnes

of asphalt

a customrecipe

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New LED lightingon the entire runway

The new Orio al Serio airport lighting provides

70% energy savings over traditional lighting

systems. In addition to the lights, all navigation

assistance lighting systems were renovated.

These are latest generation systems that allow all

runway areas to be remote controlled and fault

troubleshooting in real-time.

2,000new lights withLED technology

2726

400 km wiring

One of the accessory works that should not be

overlooked is the full replacement of cable ducts

and wiring for a total of 400 km.

This operation aimed to update the local network

and runway system infrastructure. These updates

allow for savings in terms of maintenance and

improved overall efficiency.

2928

Vitali

Work on the Orio al Serio airport runway is an

extremely significant way to evaluate the Vitali and

its partners’ potential and work methods. Proof of

how an organisation able to combine tested methods

and innovation can achieve extraordinary results,

going against the trend of delays and problems that

often characterise infrastructural works in Italy. A

virtuous example that speaks more than words on

Vitali’s identity: a group specialised in highly complex

work, that bases its competitive range on the

professionalism of over 400 experts that make up the

team and the availability of an advanced machinery

pool. Sure results in guaranteed time emerge from

this synergy.

your construction partner

real estate development

special demolitionsenvironmental reclamation|decommissioning

productionasphalt|concrete|inert material

engineering

infrastructuresroads|highways|airports

30 31

Vitali S.p.A.

via Alberto da Giussano, 15 - 20145 Milano (MI)

email: info@vitalispa.it

WWW.VITALISPA.IT