East Midlands Airport Runway ResurfacingColas has a successful track record of implementing works for the Manchester Airport Group (MAG). In 2016, this continued with contracts awarded to carry out taxiway maintenance at Bournemouth Airport, car park resurfacing at Stansted Airport, and, most recently, runway resurfacing works at East Midlands Airport.

East Midlands Airport Runway ResurfacingThe NeedThe East Midlands Airport project required Colas to rehabilitate the airport’s 2.9km 09-27 runway on behalf of MAG’s framework management contractor, Galliford Try.

The works involved removing the existing asphalt pavement and resurfacing the runway and taxiway tie-ins with a new high-quality Beton Bitumeux Aeronautique (BBA) surface course.

The works were undertaken during day and night shifts across 5 consecutive weekend closures of the runway.The project marked the fi rst time that a UK commercial airport had implemented full shutdowns across multiple weekends to allow large scale runway re-surfacing.

CASE STUDY

Colas Contracting is a trading name of Colas Limited

Key Facts

Client Galliford Try

Date November 2016 to December 2016

Duration 50,000t of asphalt material laid over 5 consecutive weekends

Value £7.3 million

Extent

2.9km runway resurfaced with BBA surface course

Over 300 operatives, staff and project management personnel and 3 mobile asphalt plants

Minimum production 600t/hour

The ApproachCollaborative working was fundamental to Colas’ approach to the East Midlands Airport project in accordance with our BS 11000 Collaborative Business Relationships accreditation.

Colas were appointed for Early Contractor Involvement (ECI) over 3 years ago to support Costain and then Galliford Try to develop an optimum solution for the project. Colas worked with designer, AECOM, as part of an integrated team and provided comprehensive BBA mix designs to meet the requirements of the specifi cation.

The ECI period allowed Colas and Galliford Try to develop the overall construction programme, clarify any design issues, develop risk contingencies, and identify further opportunities.

During the ECI period, Colas developed plans and measures to ensure the project was suitably resourced with over 300 staff and operatives required to meet the intense programme each weekend.

Colas began the delivery of the surfacing element of the project on 5th November 2016, following the carefully coordinated mobilisation of all resources to fulfi l the project requirements.

Within each 48 hour weekend possession, Colas had a planned 30 hour programme, with a 6 hour contingency window, to implement the surfacing works.

Colas teams planed off the existing Marshall Asphalt runway surface course over a width of 44.2m before laying a new BBA surface course.

In addition, material in the central 22m keel section of the runway was replaced to a depth of 165mm. The runway works involved the use of 6 paving machines, with 5 laying in echelon formation, to ensure no cold joints were created in the surface.

Colas also laid new BBA surface and regulating courses on both runway shoulders and taxiway tie-ins.

Upon project completion, Colas had laid approximately 50,000 tonnes of asphalt material. To produce the tonnages required, Colas established 3 mobile asphalt plants on-site, which were in operation simultaneously, providing a continuous supply of BBA.

In addition, material in the central 22m keel section of the runway was replaced to a depth of 165mm. The runway works involved the use of 6 paving machines, with 5 laying in echelon formation, to ensure no cold joints were created in the surface.

Colas also laid new BBA surface and regulating courses on both runway shoulders and taxiway

Upon project completion, Colas had laid approximately 50,000 tonnes of asphalt material. To produce the tonnages required, Colas established 3 mobile asphalt plants on-site, which were in operation simultaneously, providing a continuous supply of providing a continuous supply of

Colas LimitedT: 01342 711000E: info@colas.co.ukwww.colas.co.uk

CASE STUDY

Colas Contracting is a trading name of Colas Limited

Colas LimitedT: 01342 711000E: info@colas.co.ukwww.colas.co.uk

CASE STUDY

Colas Contracting is a trading name of Colas Limited

Key Benefi tsThrough close collaboration with Galliford Try and our supply chain partners, Colas was able to implement several innovative value engineering solutions:

• Joint heaters were installed on all pavers to create more robust joints for long term durability

• Box extensions were fi tted to widen the paving equipment in order to increase outputs and reduce longitudinal joints

• The Colas product, Emacol was used as a rapid breaking agent, which decreases curing times of bond coats and thus increases output rates

Pre-shift briefi ngs ensured all parties understood the requirements and constraints in place. Site plans were reviewed showing the various work locations, traffi c routes, and restricted areas for the upcoming shift. Any issues identifi ed were addressed prior to taking possession of the runway.

Continuous communication between Colas and Galliford Try allowed the works to be delivered in a coordinated manner.

Colas appreciated that the continued operation of the runway, outside of the possession periods, was essential for the airport, and so we liaised closely with the airport operations team and ensured handover deadlines were met.

To achieve this Colas monitored progress against the weekend’s hour by hour paving chart and updated the Project Manager accordingly. This hourly update ensured that any delays/issues were quickly mitigated before they impacted upon the delivery of the possession works.

Handover meetings were held to exchange information on progress, issues, and mitigation actions required.

Colas implemented several processes prior to handing over the runway at 12:00hrs each Monday at the end of the possession windows:

• Friction surveys were carried out on the newly laid BBA surface to ensure that the runway met Minimum Friction Levels (MFLs).

• Runway markings were also temporarily replaced to allow operation of the runway to Cat 1 status.

• Critical lighting was reinstalled by the AGL contractor, and FOD checks were conducted.

• Mechanical sweepers were deployed along the full length of the runway to ensure that no items of debris were left on or adjacent to the runway prior to hand back.