McCarthy Improvement & C.W. Matthews Contracting Co., Inc.

a Joint Venture

FC-6610 – Runway 8L/26R Pavement Replacement Project

Demo Time Lapse

• Demo Video (not available in presentation mode)

Contents

• Project Stakeholders• Taxiway Phase Success• Runway Phase Goals• Schedule• Pre-sawing• Demolition• Milling and Paving• Electrical• PCC Paving• Striping• Blast Pad Modifications

Stakeholders

• McCarthy Improvement

• CW Matthews Contracting Co.

• Brooks-Berry-Haynie

• Department of Aviation

• Hartsfield-Jackson Development Program

• Aviation Infrastructure Solutions

• Federal Aviation Administration

• Airlines

Job Overview

Challenges

• Schedule– 29 days for all removal, paving, grooving and striping – $850,000/Day Liquidated Damages

• Badging– All workers had OCIP training– All supervision and lead men had SIDA training

• OCIP insurance– Safety requirements

• Questionable Aggregate– workable mix design that could achieve strength:500 psi at 12-14hr, and 650 around 36-48hr; at the same

time forgiving mix and workable

• Trucking– Trucking shortage in Atlanta

• Gate Access– All removed slabs, asphalt, CTB millings and PCC through one small gate that required all entering vehicles to

be checked in

• Escorts– One escort’s vehicle per 2 trucks

• Smoothness– Maintain 5 PI on a .2 blanking band check on 7 pathways

Taxiway Phase Success

Runway Phase Goals

• Safety – Protecting employees and traveling public

• Quality – Ensuring strength, smoothness, and accuracy are paramount

• Schedule – Meeting or ahead of 29 day requirement; No rain delays

• Production

• Performance

• Partnering – Closely coordinated with HJDP, DOA, COA, OPS, FAA, Airlines , AIS, etc…

Job Overview

• Runway Closure – September 15 @ 2300 – October 14, 2014 @

2330

• Magnitude of Scope– 99,684 SY of concrete removal and replacement

– 58,723 CY of concrete

– 835,444 SF of welded wire fabric

– 45,334 Dowels to drill and epoxy

– 530+ light cans to install and pave around

Closure Plan

Schedule

• Phase 1A –Runway 8L East and West, B3 and B11

• Phase 2 – Center of Runway 8L

• Phase 3A – Eastern half of ramp 2N

• Phase 3B – Western half of ramp 2N

• Blast Pad Modifications – Approach end of 8L

Schedule – Phase 1

• Pre-sawing started 8/17/14• Runway closed 9/15/14 at

2300• Demolition started

immediately after runway closed, on western half

• Lighting installation preceded PCC Paving sequence

• PCC Paving Sequence – Lane 3W 200’ to open western end of Runway

Schedule – Western Half of Runway

• PCC Paving Sequence – Pilots = Lane 4W, 2W, then pilots on eastern half, then fill in 5W, 3W

Schedule - Eastern Half of Runway• PCC Paving Sequence – Pilots = Lane 4E, 2E then

fill in lanes on Western half, then fill in 5E, 3E

Schedule – Phase 1B

• Modified to allow Bravo to stay open during phase 1

• PCC Paving began with lane 6 of runway for eastern tie-ins

Schedule - B11

• Paved pilot lanes between 3W/6W for phase 1A and Pilots 4W for western half

• Required full strength for swapping to phase 2, reopened to air traffic.

Schedule – Phase 3A (12 days)

• 12 days – Concurrent with runway closure

• No lights

• Demolition started with dedicated machine as runway closed

• Pilot lanes – 1,3,5,7,9

• Fill in lanes – 2,4,6,8

Schedule – Phase 3B (12 Days)

• 12 days – Concurrent with runway closure

• No lights• Demolition started

with dedicated machine as runway closed

• Pilot lanes –1,3,5,7,9,11

• Fill in lanes –2,4,6,8,10

Closure Plan

Schedule – Phase 2

• Available once B11 was able to reopen• Pilot lanes 2,4,6• Hand pours 1,7• Fill in lanes 3,5

Pre-sawing

Photos from Runway 8R replacement 2006, pre-sawing phase

Western Half of Runway Demolition

• Five Slab Crab Excavators• 48,000 SY Removal of 16” Concrete• 15,800 Tons Removal CTB• 4500 LF• 4,500 Tons Asphalt Subbase Installed

Eastern Half of Runway Demolition

• Five Slab Crab Excavators• 30,900 SY Removal of 16” Concrete• 11,700 Tons Removal CTB• 3650 LF• 3,250 Tons Asphalt Subbase Installed

Phase 3A Demolition

• Four Slab Crab Excavators

• 3,275 SY Removal of 16” Concrete

• 1,100 Tons CTB

Phase 2 of Runway Demolition

• Four Slab Crab Excavators• 13,350 SY Removal of 16” Concrete• 4,400 Tons CTB• 950 LF• 1,500 Tons Asphalt

Phase 3B Demolition

• One Slab Crab Excavators

• 2,940 SY Removal of 16” Concrete

• 1,000 Tons CTB

Gate 26All trucks access through this gate

Escorts can take 2 trucks at a time

Demolition

RUNAWAY DEMOLITION

Milling and Paving

Electrical

Striping

20” Pavement Section

15” PCC is placed – Mesh D10 x D6 is laid in – 5” PCC Cover

Batch plants

• MCI CENTRAL MIXBATCH PLANT – REXCON LOGO 12

• TERRELL MATERIAL BATCH PLANT – ERIE STRAYER

Paving Crews

• Dedicated paving train 24/7 for runway paving

– 3W, 6W, B11 Pilot, 4W, 2W, 4E, 2E, 5W, 3W, 5E, 3E

• Second train for Taxiway paving B3, 3A and 3B

– 3A pilot, B3 Pilot, 3A fill in, B3 fill in, 3B Pilot, 3B fill in

Concrete Paving Train RUNWAY

RTP 500

Gomaco GSIG&Z Texture

/ CureG&Z 850 Mesh Cart

Gomaco 2600

Paving Crews

Paving Crews

Paving Crews

Paving Crews

Paving Crews

Paving Train

Concrete Paving Equipment Utilized

• Concrete Plants – 1 – North plant from Taxiway Phases– 1 – New plant on North side mobilized by Terrell Materials. Test slab performed

8/22/14– 1 – Backup plant on Sullivan Road

• Runway 8L/26R – Concrete Placers

• 2 – Gomaco 2600 equipped with vibrators and hydraulic lift gates – one back up• 1 - WWF cart • 2 – Gomaco RTP 500 – one back up• 1 – Terex 30 Ton Rubber Tire Crane (Bellamy)

– Concrete Pavers• 1 – G&Z S850 • 1- Gomaco 2800 back up

– Texture/Cure Machines• 1 – G&Z TC Machine• 1 – Gomaco TC/600 Machine

– Smoothness Indicators• 2 – Gomaco GSI – one back up

Concrete Paving Equipment Utilized• Taxiway B3

– Concrete Placer• 1– CMI MTP 4004

– Concrete Paver• 1 – Gomaco 2800

– Texture/Cure• Hand Finish

• Taxiway B11– Concrete Placer

• 1– CMI MTP 4004

(shared with Taxiway B3)

– Concrete Paver• 1 – Gomaco 2800

(shared with Taxiway B3)

– Texture/Cure• Hand Finish

Concrete Paving Equipment Utilized

• North Apron

– Concrete Placer

• 1– CMI MTP 4004

– Concrete Paver

• 1 – Gomaco 2800

– Texture/Cure

• Hand Finish

Paving Train Video

• Paving Train

PCC Paving

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