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McCarthy Improvement & C.W. Matthews Contracting Co., Inc.
a Joint Venture
FC-6610 – Runway 8L/26R Pavement Replacement Project
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
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
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
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
Schedule – Phase 2
• Available once B11 was able to reopen• Pilot lanes 2,4,6• Hand pours 1,7• Fill in lanes 3,5
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 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
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 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