Heathrow 3rd Runway Construction

Heathrow Airport, 3rd Runway Construction

© David H Moloney

Runway Construction Sequence & Methods

© David H Moloney

Runway Construction Methods

© David H Moloney

Earthworks Basecourse Ducts for ground lights

Asphalt Paving Line Marking Flight Check

M25 Tunnel under Runway Construction Sequence & Methods

© David H Moloney

Culvert under Runway Construction Methods

© David H Moloney

Earthworks Prepare Formation Floor

Walls Roof Backfill

Heathrow Airport, 3rd Runway Construction

Introduction

This Presentation shows in a straightforward way how a runway

is constructed and how the progress, safety and quality is

monitored and controlled. Also the measures to ensure that

the site is environmentally friendly.

The Presentation can be used to engage Stakeholders and to

get the Site Teams commitment to the programme. Also can be

used as a way to capture and share knowledge.

Presentation can be used for safety and induction Training for

apprentices from the nearby communities that will be

employed on the new infrastructure. The Presentation shows

what to expect prior to stepping onto site and is currently used

for Training in Safety Compliance in airside operations to avoid

safety incidents and accidents

© David H Moloney

Project Execution Plan for Runway Construction Details of how a Runway is constructed, and how the progress, safety and quality will be monitored and controlled. Also the measures to ensure that the site is environmentally friendly.

David H Moloney

10th August 2016

Brief Description

The purpose of this presentation is to give an understanding of the Methods, Plant and Sequence to construct a Runway .

This presentation can be used to engage Stakeholders and to get the Site Teams commitment to the programme. Also can be used for Induction Training and as a way to capture and share knowledge.

Project Execution Plan (PEP) details how a project will be executed, monitored and controlled.

High in Educational Value and easily understood. Recommended for Continuing Professional Development (CPD)This Video Presentation is innovative and has many beneficial uses.

http://www.slideshare.net/DavidHMoloney/runway-construction-project-execution-plan

Film at https://youtu.be/yCKLPzrDztw

© David H Moloney

http://www.slideshare.net/DavidHMoloney/runway-construction-project-execution-plan

https://youtu.be/yCKLPzrDztw

Table of Contents

© David H Moloney

Runway Construction

© David H Moloney

Runway Construction Sequence & MethodsR

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© David H Moloney

Excavate & Load Tipper Trucks

© David H Moloney

Trench Excavation with Stepped Faces

© David H Moloney

Trench Excavation with Battered Faces

© David H Moloney

Spreading & Compaction Clay fillE

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Tipper Trucks Unloading

Spreading & Compaction Clay fillE

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Backfill TrenchE

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Dozer Pushing ClayE

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Dozer Ripping GroundE

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Excavator with Hydraulic RockbreakerE

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Rock - Excavability

The excavability of rock depends mainly on the rock strength and the layer thickness. This diagram shows excavation methods for rock of various strengths and thicknesses, with a free face.

ⓒ David H Moloney

CABC ( Crushed aggregate base course )E

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Mixing Plant

Testing Compaction

Site Trial

Mixing CABCE

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Spreading & Compaction CABC ( Crushed aggregate base course )E

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Spreading & Compaction CABC ( Crushed aggregate base course ) E

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Spreading & Compaction CABC ( Crushed aggregate base course )E

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Runway Asphalt PavementR

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Brief Description

Sequence, plant and methods to construct a runway

Prime Coat Site TrialsR

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Bituminous Prime Coat shall

consist of supplying and applying

bituminous material to a previously

prepared and approved base

course in accordance with the

Specification to ensure a bond

between this surface and the

overlying course.

Runway Asphalt Pavement - Prime CoatR

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Runway Asphalt Pavement - 4 Pavers working togetherR

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Runway Asphalt Pavement - 4 Pavers working togetherR

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Cutting JointR

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Runway Asphalt Pavement - Line & Level R

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Checking asphalt level by Dip measurements

String line used for Level & line reference


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Runway Pavement - MarkingR

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Runway Pavement – Cleaning surface with rotating water jetsR

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Runway Pavement – Cleaning surface with rotating water jetsR

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Runway Pavement – Test for Skid Resistance

Roads &

Pavin

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Runway Pavement R

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Using the Douglas Mu-Meter continuous friction measuring equipment

Runway Pavement – Test for Smoothness using Rolling Straight Edge

Roads &

Pavin

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Runway Pavement – Test for Texture by Sand Patch testR

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Airfield Ground Lights Ducts & ChambersM

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Airfield Ground Lights M

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Airfield Ground Lights Ducts & ChambersM

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Airfield Ground Lights Excavate Trench in CABCM

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Airfield Ground Lights – Concrete DuctsM

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Airfield Ground Lights – Surface Inset LightsM

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Airfield Ground LightsM

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Jig to Level Pot

Airfield Ground Lights - Core drill for Inset LightM

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Airfield Ground Lights Fit Pot with JigM

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Precast Yard - Chambers M

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Delivery of Precast Chambers M

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Jointing HDPE Ducts Jointing HDPE Ducts

Precast Chamber Grouting Inset Light Pot

ILS Localiser Antenna & Approach LightsM

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Provides lateral radio guidance to an aircraft approaching and landing on a runway

Approach LightsM

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Approach LightsM

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Used by the pilot to align the aircraft visually with the runway centreline.

ILS Glide Path AntennaM

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Provides radio vertical guidance to an aircraft approaching and landing on a runway

DVOR Ground StationM

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Omni Directional Radio Range (VOR) is a radio navigation system for aircrafts, so an aircraft can determine their position and stay on course.

Airfield Lights - SubstationM

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Contains switchgear, protection and control equipment

Airfield Lights - SubstationM

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Contains switchgear, protection and control equipment

Airfield Lights – Taxi Guidance SignsM

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Taxi guidance signs provide direction and information to taxiing aircraft.

Concrete Slipform PavingR

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Brief Description

Horizontal slip forming for concrete pavement. The process

consists of placing and spreading low slump concrete on the

ground in front of a paver that slips over the concrete and

extrudes strips of slabs.

Slipform Concrete PaverSpreader

Texturing & Curing

Concrete Slipform Paving – Texturing MachineR

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Concrete Slipform Paving - Slipform MachineR

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Concrete Slipform Paving – Placer / Spreader MachineR

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Concrete Slipform Paving R

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Concrete Slipform Paving – Drilling holes for dowelsR

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Concrete Slipform Paving – Drilling holes for dowelsR

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Pavin

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Runway Concrete PavementR

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Milling / Planing MachineR

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Used to remove part of the surface of a paved area

Cable LayingP

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Brief Description

132 kVa Cable laying .

Cable Laying P

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Cable Laying P

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Cable Laying P

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Cable Laying ⓒ David H Moloney

Cable Drum Stand Cable pulled on rollersCable Winch

Cable Drum Unloading Cable on rollers Cable Testing prior to Backfilling

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Horizontal Directional DrillingP

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Brief Description

Horizontal Directional Drilling under a taxiway.

Process

1. A pilot hole id drilled to the designed profile

2. A reamer is pulled back through the hole to enlarge it

3. A pipe string is pulled into the hole.

Horizontal Directional DrillingP

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Micro TunnellingT

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Micro Tunnelling Sequence David H Moloney

ⓒ David H Moloney

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FencingM

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Brief Description

Fencing.

Sequence of construction;

1. Clear and grade the ground.

2. Fix corner and straining posts.

3. Fix intermediate posts.

4. Fix line wire, chain-link and razor wire.

5. Construct concrete ground beam

FencingM

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FencingM

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FencingM

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FencingM

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Fencing DeliveryM

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Article on Muscat Airport Runway Link http://www.ccc.me/pdf/bulletins/bulletin103.pdf

Runway Construction Pavement Details & Mixes

Runway Asphalt Runway Ends Concrete

Concrete Delivery Order - RecordC

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It is important to record orders for

concrete deliveries.

The form can be adapted for

other materials e.g.

reinforcement.

Flight CheckTe

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Brief Description

Aircraft performing flight checks

on new Instrument Landing

System

Concrete

Reinforced Wall Construction Sequence

ⓒ David H Moloney

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Brief Description

The sequence to construct a reinforced concrete wall is as

follows:

Tie the reinforcement.

Erect stop-ends and the wall shutters.

Pour and vibrate the concrete mix.

Remove the shutters after the concrete has hardened.

.

Cycle Time Pour per Day

Reinforced Wall Construction Sequence

ⓒ David H Moloney

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Culvert ConstructionC

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Brief Description

Sequence to construct culvert

with head walls.

Culvert ConstructionC

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Oil InterceptorM

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Used to capture oil / fuel from leaks or spillages that are washed down drains every time it rains.

Oil InterceptorC

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Excavation for Underground Pump stationE

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Brief Description

Faces of excavation Stepped &

Well-point Dewatering used.

Concrete MixG

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A concrete mix contains 5 major

elements: cement, water, coarse

aggregates, fine aggregates (sand) and

air in different proportion. Additional

elements such as pozzolanic materials (fly

ash, silica fumes or slag) and chemical

admixtures can also be incorporated to

the mix to increase its properties.

Vibrating Concrete

ⓒ David H Moloney

Co

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Airside Restrictions

Stakeholders Engagement

Method of Work Plan (MOWP)

A Method of Working Plan (MOWP) is prepared when the normal operation of an aerodrome is

disrupted through aerodrome works and the risk to aircraft operations is increased. Stakeholders

likely to be significantly affected by the proposed works will be given the opportunity to participate

in the planning process.

The MOWP will clearly set out the following: • the scope of work and the stages of carrying out

the work; • how the works are to be carried out and the restrictions on the works organisation; •

how the aircraft operators and pilots will be told, through NOTAM, of the restrictions to aircraft

operations at each stage of the work; • identify any changes necessary to aerodrome markings

and lights as the works progress; • drawings to illustrate work arrangements and changes to

declared distances, taxiing routes, etc.; and • identify persons responsible for the works and those

accountable for ensuring safety of the aerodrome facilities to aircraft operations.

Airport Stakeholders

Operations G.M.

Technical Services G.M

Senior Aviation Manager

Chief Fire Officer

Project Manager

Sr. Maintenance Manager

Operations Reediness Team Leader

Certification & Compliance Manager

Airfield Duty Manager

Airport Duty Manager

HSE Specialist

DGSAS, Director of Airports

DGSAS, Aerodrome Certification

CAA Air Traffic Control –Tower

CAA Chief of Tower

Police

Ground Handling Agent

Airport Refueller Companies

Airplane Wingtip ClearanceM

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Brief Description

Regulation distances shown

for wingtip clearance.

Airplane Wingtip ClearanceM

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Taxiway Reconstruction AirsideM

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Brief Description

Regulations regarding working adjacent to

a live runway.


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Working Airside to Upgrade Taxiway

Asphalt Pavement Laid on Existing Concrete Pavement Temporary Gate and Fence

Excavation Planing at Runway tie-inFill –Crushed Aggregate Rake sealant out of Joints


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Contractors Temporary Facilities

Temporary Contractors Site Facilities

ⓒ David H Moloney

Brief Description

Site Offices, Camp Accommodation for 1,250 workers, Canteen, Recreation, Fabrication shops, Stores, Plant Yard. In five locations along the route.

Welfare Facilities

ⓒ David H Moloney

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Toilets – Washing

Canteen, Drying Room, Toilet & Generator

Site Hoarding examples

ⓒ David H Moloney

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Temporary Fence type 1

ⓒ David H Moloney

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Brief Description

Examples of temporary security fences that are higher than the usual


ⓒ David H Moloney

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ⓒ David H Moloney

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Brief Description

Temporary fence on precast beam for airport.


ⓒ David H Moloney

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Dewatering

ⓒ David H Moloney

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Brief Description

Construction dewatering is the removal or drainage of

groundwater and or surface / rain water usually by

pumping to keep the works dry.

Dewatering

ⓒ David H Moloney

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Brief Description

Construction dewatering is the removal or

drainage of groundwater and or surface /

rain water usually by pumping to keep the

works dry.

Dewatering

ⓒ David H Moloney

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Wheel Wash Drive-through

ⓒ David H Moloney

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Wheel Wash Drive-throughG

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Temporary Electricity Supply & Tower Lights

ⓒ David H Moloney

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Asphalt Batching YardG

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Concrete Batching Yard 3 Nr MixersG

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Concrete Batching Plant David H Moloney

ⓒ David H Moloney

Concrete batching plant comprises - concrete mixer, control cabin, silos for cement and fly ash, aggregate bins and conveyor belt system to feed the mixer. Also aggregate storage bays and water storage tanks. The mixing is computer controlled and has a dynamic screen display, showing the process. Material storage capacity to match two days concrete production

Concrete Batching Yard 3 Nr MixersG

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Crushed Aggregate Batching PlantG

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Crushed Aggregate Batching PlantG

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Quarry & Aggregate ProductionG

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Quarry & Aggregate ProductionG

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Reinforcement Cutting & Bending Yard David H Moloney

ⓒ David H Moloney

Reinforcement in 12 m lengths. Delivery in 3 ton Bundles Reinforcement cut to length by Shearing Machine

Reinforcement Bent to Shape by Bending Machine Reinforcement that is cut and bent is Bundled for delivery to work site

Reinforcement Cutting & Bending

ⓒ David H Moloney

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Setting out & Surveying



Safety & Environmental

Emergency Phone Numbers & Response

HSE Monitoring & Reporting - Dashboard Dashboard is a single page, graphical representation of

current HSE Issues and historical trends

Site Safety Posters examples

Safety Precautions

Personal Protective Equipment (PPE)H

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Personal protective equipment (PPE) is protective clothing, helmets, goggles, or other garments or equipment designed to protect the wearer from injury or infection

Existing Underground Utilities

ⓒ David H Moloney

Ea

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Brief Description

Before digging

establish the location

and route of

underground utilities.

Locator to find Utilities

Spray Paint to mark pavement

Existing Underground Utilities & Overhead Cables - Safety Measures

ⓒ David H Moloney

Ea

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Trench - Safety Measures H

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Safe

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Envir

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Trench - Safety Measures

ⓒ David H Moloney

Health,

Safe

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Envir

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Safety Training on Site M

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The purpose of safety training is to provide the knowledge necessary to

perform a job safely

Safety Training Matrix M

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The purpose of safety training is to provide the knowledge necessary to

perform a job safely

Emergency Response Drill H

SE

Drills and exercises are used to rehearse anticipated emergency scenarios

Safety DocumentsH

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Safe System of Work.

To provide a safe system of work is a legal requirement. What this means is that before you ask an employee to do a

job. You ensure that he has received training, has the appropriate personal protective equipment, the work area is safe

and he is unlikely to be injured or cause damage by carrying out the assigned task.

Project Management Plan for Health, Safety, Security and Environment. also Known as (HSSE Plan)

The Project HSSE Management Plan details how safety on site will be managed.

Project Procedures for Health, Safety, Security & Environment

Details the safe way to undertake a task

Methods Statements

Are prepared in advance of starting work, to plan a Safe System of Work on site for all activities that carries a risk. The

contents of a Method Statement, typically include:- Scope & Location of the Works, Programme, Roles & Responsibilities

of Staff. Resources, Work Methodologies and Risk Assessment.

Slide 1 of 2

Safety DocumentsH

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Safety Risk Assessments

Are prepared to identify and evaluate risks, to adopt control measures to reduce or eliminate risks.

COSHH Sheet

The purpose of the Control Of Substances Hazardous to Health sheet is to identify how to prevent or adequately control

workers exposure to hazardous substances.

Permit to Work.

Is a management system used to control high risk activities by ensuring safety measures are in place prior to starting

work.

Types of work for which permits will be required include:

Excavation and the digging of trenches.

Working at height, including on roofs.

Working in confined spaces, for example entering a manhole.

Hot work, which is welding, soldering or cutting steel with angle grinders or by gas torch.

Slide 2 of 2

Environmentally Friendly Site Air, Noise, Water & Soil Pollution

Hazardous Substances Symbols H

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COSHH stands for the Control of Substances Hazardous to Health

Shown are the new hazard symbols

Water Pollution PreventionG

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Segregation of Waste H

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Segregation of waste for proper disposal and recycling. Less waste goes to landfill and hazardous waste is treated to make it safe.

Colour Code for Skips & Bins

Putting Waste Concrete to use

ⓒ David H Moloney

Health,

Safe

ty &

Envir

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Precast bases for signs and hoarding, Precast blocks for walls.

Administration

Organogram

Brief Description

Shown are the line and

lateral relationships

between the various team

members and their relative

position in the site

organisation.

Staff Responsibility Matrix

Staff Directory

Brief Description

List of staff and their

contact details

Daily Work Record

Brief Description

Daily Work Records showing the

allocation of resources, materials and

work activities carried out daily.

Quotations Comparison Sheet

Filing System

Quality Assurance

Quality Assurance Dashboard Dashboard is a single page, graphical representation of

current statistics and historical trends

Runway Asphalt Pavement - TestsR

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Quality Assurance Tests

Runway Concrete Pavement - TestsR

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Runway LaboratoryR

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Laboratory

ⓒ David H Moloney

Asp

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Programme & Progress Monitoring

Progress Monthly, Monitoring & Reporting - DashboardDashboard is a single page, graphical representation of current

progress and historical trends

Histogram Charts for Resources & Outputs

Manpower per Discipline

Concrete per Location

Man-hours for each month of the Project

Quantity for each month of the Project

ⓒ David H Moloney

Brief Description

Histograms shows resources etc. for each month of a project.

Plant & Equipment List & Worker’s Job Titles

ⓒ David H Moloney

Programme for Construction

Gantt Charts to plan and schedule projects

Primary Substation-

Chiller Plant

Pump House

IRRIGATION WATER TANKS

Irrigation Pump House-

POTABLE/FIRE WATER TANK

Programme using Timeline & 3D Images

Airport Central Utility Yard

Pump House

Piling

Primary Substation

Chiller PlantPump House

Irrigation Pump House

Primary Substation-711

Chiller Plant-714Pump House-715

Irrigation Pump House-716



IRRIGATION WATER TANK


















POTABLE/FIRE WATER TANK

Miscellaneous

Structural Steel

Airport Roof Truss

ⓒ David H Moloney

Str

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Brief Description

Roof Truss 190 tonne in weight. Sections welded together on

trestles and the truss is lifted into position.

Airport Roof TrussS

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Roof Truss Sections Roof Truss Sections assembled on trestles

Trusses weigh 190 tonnes Crane Demag CC 8800

Airport – Roof Section Mock-up S

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Airport Piers Roof Frames S

tru

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Sections assembled on trestles

Pedestrian Boarding Bridges & Bridge House S

tru

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Pedestrian Boarding Bridges & Bridge HouseS

tru

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Pedestrian Boarding Bridges & Bridge HousesS

tru

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Mock-up

Airport Roof TrussS

tru

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Airport Roof TrussS

tru

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Piers ConstructionS

tru

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Piers ConstructionS

tru

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Roof Covering

ⓒ David H Moloney

Str

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Brief Description

Sequence is

Fix bottom sheet

Fix Vapour barrier

Fix Top Hat section and clips

Fit Insulation

Fix top sheet

Roof Covering

ⓒ David H Moloney

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Roof Covering

ⓒ David H Moloney

Str

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Roof Covering

ⓒ David H Moloney

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View from ATC TowerM

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Tower ConstructionC

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Brief Description

Air Traffic Control Tower constructed

using a jump-up shutter system.

ATC Tower CladdingC

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Production by David H Moloney

My YouTube Channel link: https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ

https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ

Engineering

Heathrow 3rd Runway Construction