Project Execution Plan for Muscat Runway Construction, Oman

Project Execution Plan includes Sequence, Resources and Methods
Contents David H Moloney email - Davmol.moloney@gmail.com
1 Cover Sheet & Contents
2 Pavements Summary Images
3 Sequence of Work Activities
4 Temporary Roads & Gates
5 Site Facilities Location Map
6 Temporary Fence & Gates
7 & 8 Quarry & Aggregate Production
9 Precast Yard
10 Drainage Culverts
11 Dewatering
12 Security Fence & Gates
13 Crushed Aggregate Base Course
14 > 21 Asphalt Pavement
22 > 24 Concrete Pavement
25 Pavement Markings
26 > 27 Airfield Lighting
28 Runway ILS & Signage
29 > 44 Health, Safety, Security & Environmental
45 > 78 Articles
79 > 87 Buildings & Structures
Muscat Runway Construction
Page 1 of 87

Airport Pavements Construction - Poster
Quarry & Aggregate Production
Crushed Aggregate Basecourse
Asphalt Batching Plant
Concrete Batching Plant Other Work Activities
Airfield Concrete Pavement
David H Moloney
Crushed Aggregate Basecourse
Asphalt Pavement
3D Image of Operation Aggregate Production
C Aggregate Batching Plant C A Batching Yard
Asphalt Batching Plant Asphalt Batching Plant
Batching Plant Yard Concrete Batching Plant
Site Trial
Paving Machine Roller
Laydown Laydown & Compaction Overview
Stop-end & Dowel Assemblies Machines Types Machines
Placing Ground Light Pavement Marking Flight Check to calibrate ISL
Page 2 of 87

Runway Construction
Sequence, Methods & Plant
Page 3 of 87

Gate 1
Gate 2
Gate 3
Gate 4
Page 4 of 87

Muscat Airport Expansion
David 26th May 2011
Temporary Airport Security Fence & Gates
Page 6 of 87

David H Moloney Quarry Operation & Aggregate Production
Quarry Aggregate Processing Yard
Rock type - Gabbro an igneous rock. Grey in colour. Moderately strong to strong.
Total quantity is 15 million m3 Capacity 120m3 per hour Total to be screened 2.7 million m3
Crushing Stages
Primary Crusher Secondary Crusher 3rd Stage Shaping
Metso LT 124 Capacity 124m3/hr Metso HP 200 Barmac Metso 410 NW
Jaw type crusher Cone Type Crusher Vertical Shaft Impactor Screening Plant
Maximum Feed Size 700 mm Maximum Feed Size 150 mm Maximum Feed Size 40 mm To produce product fractions
To break rock down to max 150mm To break rock down to max 25mm To produce cubically shape Aggregate 0-4mm, 4-12mm, 12-19mm, 19-25mm
Sequence - Crush, Screen 0-
4mm, 4-12mm, 12-19mm &
19 -25mm, Load and Haul to
Sequence - Strip Overburden, Drill &
Blast benches to fragment rock,
Secondary breaking of any oversized
Page 7 of 87

Airport Precast Yard
Page 9 of 87

Work Method Chart
Box Culvert - 2 Cell
Muscat Airport Expansion Concrete :- C40 Slump 150 +/- 30
David H Moloney Nov 2010 Rebar cover :- 75 mm
Step 1 Step 2 Step 3
Bases in Hit & Miss sequence Walls Infill bases & Roof Completed
Hot Weather Concrete
Specification requirements Actions to control temperature
Max Placement Temperature 32*C Flaked ice is used in mix to control temperature
Max Core Temperature 65*C Pour in evening in hot weather
Maximum differential temperature 20*C Proper Curing S 19
Page 10 of 87

David H Moloney
Excavation with Well point Dewatering Excavation with Well point Dewatering Excavation with Well point Dewatering Excavation with Well point Dewatering
Settlement Lagoon Filling Tanker trucks for Dust suppression Filling Tanker trucks for Dust suppression Sea outfall
Dewatering Operations - Infographics
Page 11 of 87

David 26th May 2011 Work Method Chart
Airport Security Fence
Including Camera & Light Posts
Reference - Method Statement ref # 224
Scaffold tower on wheels
Method
JCB with Auger for holes
Lift in posts with JCB
Posts will be temporarily help in position using triangular props
Access to Heights
Step ladder for fixing line, barbed wire and chainlink.
Scaffold tower on wheels for fixing razor wire Materials
Sequence of Construction Intermediate Posts 75 mm dia @ 3m c/c Foundations C30 450mm dia
Corner & End Posts 168 mm dia
Clear Scrub & Grade ground Straining Posts 169 mm dia @ 66m c/c
Fix Corner & Strainer Posts Line Wire 5 strands
Fix Intermediate Posts Chainlink Ground Beam 300 mm square
Fix Wire Razer Wire 2 Coils 750mm dia coils
Fix Signs Barbed Wire 6 strands
Concrete ground beam Camera Posts @ 400m c/c
Install precast foundations for Light & Camera Posts Light Posts @25m c/c
Install poles by Hiab Signs @25m c/c
Page 12 of 87

CABC (Crushed Aggregate Base Course) - Laying & Compaction
Muscat Airport Expansion Wet Mix Macadam Mixing Plant On site Specification Requirements
Capacity: 80 to 100 cu.m. per hour
David Moloney 31/08/2010
Size From To
References 37.5 mm 100%
Specification - Civil Series 300 25.0 mm 60% 100%
Method Statement - # 23 rev.1. PHOTO 19.0 mm 55% 85%
I.T.P. (Inspection & Test Plan) - # 14 4.75 mm 35% 60%
2.00 mm 25% 50%
0.425 mm 15% 30%
Material 0.075 mm 8% 15%
The moisture content shall be the optimum value +2%/-1%.
Level, Grade & Alignment Control
Level & Grade Alignment
Longitudinal By Stringline mounted on pegs free standing
1st paver has 2 String lines
2nd Paver has 1 String line & Matching shoe
Rollers
50m to 100m lag between pavers
Tractor Units Pavers
22 cu.m. Capacity 3 axle Trailers VOGELE Super 1800
Water Tanker 18 m3 Rigid Lorries 3 axles 14m3 with Sensor arms that follow stringline for level and longitudinal grade
Damper surface prior to laying Output approx 1,000 tonnes per day per paver
After Care - Surface to be kept Damp for 3 days Note - add 25% to layer thickness to allow for compaction.
Level & Grade Control Equipment Tests QA
Steel Pags free standing @ 10m c/c offset 0.5m from layer edge Asphalt 160mm thick Workmanship
Supporting taut string line , Paver with sensor arm Compaction 100% Dry Density - Test by Sand Replacement Method
String line set 100mm over finish road level Level - 10mm + 5mm Test by Engineers level
Pave Width & Laps Materials Grading Analysis
Strip width approx 6 metres Rockfill Optimum moisture content
Longitudinal joints 500mm stagger between layers Compaction 100% the maximum dry density
Transverse joints 3m stagger between layers
Cross Section
The "Proctor Test" is a laboratory test used to determine the "ultimate" dry density and
"optimum" moisture content for the CABC. ( Appro 2.5t/m3)
CABC 370mm thick in 3# layers
Crushed Aggregate Basecourse with moisture
content of between 5.5 to 8.5%
Firstly - Single Drum roller 2 passes on static, 2 passes on high vibration & 4
passes on low vibration
Secondly - PTR roller 2 passes followed by single drum roller 2 passes to polish
off.
Grading Requirement
Specification Limits
By Testing, the Moisture-Density relationship for the material was found to have
a Optimum Moisture Content of 6.5%
Single Drum Hamm 3411 & PTR (Pneumatic Tyre Roller) Hamm GRW
18
Aggregate fractions & water is mixed continuously by a twin shaft
pugmill mixer to produce the CABC that will fall within the
gradiation envelope and have a moisture content of the optimum
valve of 6.5% +2% / -1%. Aggregate fractions 0-4mm, 4 to
25mm & 25 to 37mm
Page 13 of 87

Level Control
1 For Base & Binder courses
Stringline & Joint-matching Shoe or averaging beam
2 For wearing course
David H Moloney August 2011 Method using 2 # Pavers working in Echelon Set paver screed to achieve a compacted thickness of 40mm
Contract:- Muscat Airport Expansion new Runway
References - 1 Method Statement # 40 Level Tolerances Spec Series 400, page 34
2 Specification Series 400 Asphalt Paving Surface +/- 6mm
3 ITP for Bituminous Pavement Activities SE-CTJ-01CW-PLN-00006 Under Straight edge 3mm with 3 m long beam
Level Equipment Marini Asphalt Batching plant
Lead Paver 2 # stringlines Model - Top TOWER 4000 P
Trailing Paver 1 # stringline & joint-matching shoe Plant Capacity - 300 tonnes per hour
Pins set at 10 centres with wire 100mm over finish level Mixer batch Capacity - 3.5 tonnes
Hot mix Storage - 126 tonnes
Joint Pattern across runway
South
Wibau Asphalt Batching plant
Asphalt Batching Plant Schematic Plant Capacity - 180 tonnes per hour
Mixer model - WKM 250-4
250 tonne with 4# screens
Batching Plants Capacity
Marini 300 t / hr (TopTower 4000 P)
Wibau 250 t / hr
Total 550 t / hr
Take output @ 450 t / hr
Vogele Super 1900-2 tracked Pavers
Testing Extending Screed type AB 600-2 TP
Levels by Engineers level
Prime Coat - apply by lorry with spray bar @ 90 *C & allow to cure for 24 to 48 hours Smoothness by Straight Edge
Compaction by Cores
Surface Preparation - remove loose material & dirt with mechanical brush Ingredients by Sample to Lab
Temperature by Digital Thermometer
Asphalt Paving - Outputs & Pave Speed
Lorry 35t Round-trip Cycle Time Length of runway appro 5,000 m Train of Laydown & Compaction Plant PTR - Pneumatic Tyre Roller
Travel from batching plant to site Av 5km 10 minutes
Thickness 7.5m strip t/m
Loads
per hour
Lorry
unload
cycle
metres
per hour
Tonnes
per hour
per Paver Delivery :- Tippers & Tractor units with trailers
Queue, Reverse, Unload & Pull out 10 minutes Wearing Course 40 mm 7.5m x 1m x 0.04m x 2.6t/cm 0.78 t/m 6.6 # 9 min 290 m 225 t / hr Pavers:- Asphalt Paver - Vogele Super 1900-2
Return to batching plant 10 minutes Binder Course 50 mm 7.5m x 1m x 0.05m x 2.6t/cm 0.98 t/m 6.6 # 9 min 225 m 225 t / hr Site Pave width 7.5 m Capacity 225 t / hr / paver
Mix & Load 10 minutes Base Course 70 mm 7.5m x 1m x 0.07m x 2.6t/cm 1.365 t/m 6.6 # 9 min 160 m 225 t / hr Rollers :- PTR Pneumatic Tired Roller - Bomag BW 25 RH 25 tonne
Total 40 minutes Prime Coat MC70 Applied to CABC surface - 0.5kgs to 0.6 kgs per m2 Application temperature 90*C +/-5*C PTR Pneumatic Tired Roller - Bomag BW 24 R 24 tonne
=> 10 # Lorries capacity 35t required Tack Coat SS-1 Between asphalt layers - 0.2kgs per m2 to 0.35 kgs per m2 Application temperature 20*C to 70*C Tandem vibratory Roller - Bomag BW161 AD-4 10 tonne
Compaction of Asphalt Roller Pattern - Temp 121 to160*C Temperatures
For 7.5m wide strip & Output 225t/hr Rate of paving 290 m per hr or 5 metres per minute Paver :- Vogele Super 1900-2 Tracked Paver Storage of Bitumen 150*C
Aim - to achieve target density and smoothness of surface Mixing 165*C Incidental Plant & Equipment Steel Tandem Drum Roller
Initial or Breakdown Rolling Intermediate Rolling Finish Rolling Laying 150*C Mechanical Suction Brush
Initial Rolling min 150*C Roller with cutting wheel for longitudinal joints
Cut longitudinal Joint max 80*C Road Saw for transverse Joints
Water Bowzer & Welfare Facility with Toilet
Roller type : Steel Tandem RTR Steel Tandem
Pneumatic Tyre Roller Ballasted to 20 tonne
Typical Crew
Make & model : BW 161 AD-4 BW 25 RD BW 161 AD-4 Engineer Tandem Roller Operatives Environmental Issues - Wastage & Efficiency
# of Rollers 1 # per 7.5m strip 1 # per 7.5m strip 1 # per 2 x 7.5m strips Supervisor Paver Operator Road Planer
# of Passes : 4 # 6 # 2 # Foreman Rake Hand x 2#
Vib / Static : 2 # Static & 2 # Vibration Static 2 # Vibration & 2 # Static Extending Screed type AB 600-2 TP Setting-out Surveyors Labourer x 4#
Weight ballasted Varible Pave Width 3m to 6m , with bolt on extensions to 9.5m Screw man Levels x 2#
Speed : 5 Km/hr 4.5Km/hr 8 Km/hr PTR Roller Operator x 2# Banksman
Tyre Pressure : Pass is "one coverage" by the roller in one direction Breaks for meals 30 minutes maximum
Pneumatic Tyre Roller (PTR) used to knead the mix and achieve most compaction.
Joints Construction Details:- 1 Traverse : Temporary ramp to allow rollers to pass, prior to restart vertical joint cut, stagger joints across adjacent strips by 3 metres. Ingredients Approximate Weights
2 Longitudinal : Add extra 100mm width to pave width for cutting back, offset joints by 300mm, cut with roller wheel when asphalt is below 80* C . Paint joints with tack coat Bitument 60/80 = 4.8% of mix weight Lorry tanker for Prime & Tack Coat
Compaction Requirement :- 94% of Gmm ie Max theroretical Note :- Vertical joint surfaces sprayed with tack coat, particular attention paid to ensure compaction on hot side of joint. Polymer 3.8 kgs per tonne of mix
Phoenix Model FC 8000 with spray bar, pressure pump
and devise to measure rate of application
Ensure level of aggregate layer under the asphalt base course is not low. As the daily crew
cost if fixed, seek ways to improve the daily output without compromising quality.
10 tonne 10 tonne
Lorry mounted Bitumen Sprayer c/w hand lance for
cold joint sealing
Material Waste - Keep tight control by reconciling daily the quantity of bitumen used at the
batching plant and asphalt mix used on site, against the theorical to establish the daily waste
factors.
Runway Asphalt Laydown & Compaction
Exerts both vertical & horizintal force to knead the
asphalt for high compaction, Tyre pressures can be
altered for different applications
25 tonne
5 m/min
4 m/min
2.6 m/min
Lorry load 34 t
43 m / load
34 m / load
24 m / load
Pave Speed
Roller Pattern to be determined by Compaction Test Strip for checking
density & smoothness, detailing sequence of rollers, # of passes, speed of
rollers and vibratory or static passes.
60 lbs/in
Main Parts
1. Cold bins 9. Hot Bins
2. Cold feed gate 10. Weight box
3. Cold Elevator 11. Mixing unit - pugmill
4. Dryer 12. Mineral Filler storage
5. Dust Collector 13. Hot asphalt cement storage
6. Exhause stack 14. Asphalt weight bucket
7. Hot elevator
8. Screening unit
Initial aka
Breakdown Rolling
Intermediate Rolling
for further compaction
Finish Rolling
for removing marks,
creases & to polish
surface
Page 14 of 87

Runway Asphalt Laydown & Compaction
Jointing Pattern & Laying Sequence across Runway
David H Moloney
15th Feb 2011 Level Control
Stringline & Joint-matching Shoe or averaging beam
Spec Series 400, page 34
2 For wearing course
Set paver screed to achieve a compacted thickness of 40mm
using averaging beam workin off binder couse
Level Tolerances
Surface +/- 6mm
Under Straight edge 3mm with 3 m long beam
Joints
Allow extra 80mm to 100mm paving width for cutting back
Cut back joints with roller & cutting disc or planer
Longitudinal Joints - 300mm joint stagger between layers
Transverse Joints - 600mm joint stagger between layers
Blast Protection Shoulder Runway & 3m between adjoining lanes
50mm Asphalt 40mm Asphalt Wearing 40mm Asphalt Wearing Level Equipment
200mm Crushed Aggregate 50mm Asphalt Binder 50mm Asphalt Binder Lead Paver 2 # stringlines
Rockfill 250mm Crushed aggregate 70mm Asphalt Base Trailing Paver 1 # stringline & joint-matching shoe
Rockfill 370mm Crushed Aggregate Pins set at 10 centres with wire 100mm over finish level
Rockfill
Contract:- Muscat Airport Expansion new Runway
References -
1 Method Statement # 40
2 Specification Series 400 Asphalt Paving
3 ITP for Bituminous Pavement Activities SE-CTJ-01CW-PLN-00006
Batching Plants Capacity ( Realistic)
Marini (TopTower 4000 P) 280 t/hr 260 t/hr
Wibau 180 t/ hr 140 t/hr
460 t/hr 400 t/hr
Testing ( ITP ref # PLN-00006 )
Levels by Engineers level
Prime Coat - apply by distributer lorry with spray bar @ 90 degrees & allow to cure within 24 to 48 hours Smoothness by Straight Edge
Compaction by Core or Nuclear
Surface Preparation - remove loose material & dirt with mechanical brush Ingredients by Sample to Lab
Joints Preparation - Use Compressor & blow pipe Temperature by Digital Thermometer
Asphalt Paving - Outputs & Pave Speed Layer Thickness by Cores
Lorry 30t Round-trip Cycle Time Length of runway appro 5,000 m Train of Laydown & Compaction Plant
Travel from batching plant to site Av 5km 10 minutes
Thickness 7.5m strip t/m
Loads
per hour
Lorry
unload
cycle
metres
per hour
Tonnes
per hour
per Paver Delivery :- Tippers & Tractor units with trailers
Queue, Reverse, Unload & Pull out 10 minutes Wearing Course 40 mm 7.5m x 1m x 0.04m x 2.6t/cm 0.78 t/m 5 # 9 minutes m 100 t / hr Pavers:- Asphalt Paver - Vogele Super 1900-2
Return to batching plant 10 minutes Binder Course 50 mm 7.5m x 1m x 0.05m x 2.6t/cm 0.98 t/m 5 # 9 minutes m 150 t / hr Site Pave width 7.5 m Capacity 150 t / hr / paver
Mix & Load 10 minutes Base Course 70 mm 7.5m x 1m x 0.07m x 2.6t/cm 1.365 t/m 5 # 9 minutes m 150 t / hr Rollers :- 1# PTR Pneumatic Tired Roller - Bomag BW 25 RH 25 tonne
Total 40 minutes Prime Coat Under Asphalt Base course - MC 70 0.50 kgs per m2 Application temperature 90*C 2# PTR Pneumatic Tired Roller - Bomag BW 24 R 24 tonne
=> 10 # Lorries capacity 30 t required Tack Coat Between asphalt layers - Css-1H 0.2kgs per m2 to 0.35 kgs per m2 Application temperature 20-70*C ? ( Trial to do) 4# Tandem vibratory Roller - Bomag BW161 AD-4 10 tonne
Note :- Paving Output determined by Lorry Cycle time to Reverse, Unload into Paver and Pullout = 12 minutes => 5 loads per hour @ 30 tonnes = 150 tonnes per hour
Note - All information subject to Paving Trial.
2 # Pavers in Echelon
Pavement Construction
Base & Binder
Course
Wearing
Couse
m / load m/min
m / load m/min
Roller Pattern to be determined by Site Trials
Lorry load 30 t Pave Speed
m / load m/min
Initial aka
Breakdown Rolling
Intermediate
Rolling
Finish
Rolling
C
L
% S lo p e % S lo p e
% S lo p e
% S lo p e
% S lo p e
% S lo p e
Page 15 of 87

21st April 2011 Level Control
Contract:- Muscat Airport Expansion Stringline & Joint-matching Shoe or averaging beam
David H Moloney Spec Series 400, page 34
References - Specification Requirement for Asphalt Paving Trial
1 Method Statement Ref # SE-CTJ-01CW-MST-00040 Specification series 400 Bituminous Pavement Pages 27 & 28 Clauses 147 to 155
2 Specification Series 400 Bituminious Pavement Level Tolerances
3 ITP for Bituminous Pavement Activities Ref # SE-CTJ-01CW-PLN-00006 Surface +/- 6mm
Under Straight edge 3mm with 3 m long beam
Location Joints
To be decided Allow extra 80mm to 100mm paving width for cutting back
Cut back joints with roller & cutting disc or planer
Longitudinal Joints - 300mm joint stagger between layers
Level Equipment Transverse Joints - 600mm joint stagger between layers
70 mm thick Asphalt Base -course on Testing ( ITP ref # PLN-006 ) Lead Paver 2 # stringlines & 3m between adjoining lanes
MC 70 Prime coat on Levels by Engineers level Trailing Paver 1 # stringline & joint-matching shoe
120 mm Crushed Aggregate Base Course layer on Smoothness by Straight Edge Pins set at 10 centres with wire 100mm over finish level
Rockfill Compaction by Core or Nuclear
Ingredients by Sample to Lab
Temperature by Digital Thermometer
Layer Thickness by Cores
Train of Laydown & Compaction Plant
Delivery :- Tippers & Tractor units with trailers
Pavers :- Asphalt Tracked Paver - Vogele Super 1900-2
Equipped with extending screed, tamper and vibrators, auger and conveyor.
Rollers :-
2# PTR Pneumatic Tired Roller - Bomag BW 25 RH 17.76 to 25 tonne
2# Tandem vibratory Roller - Bomag BW161 AD-4 10 tonne
Surface Preparation - remove loose material & dirt with mechanical brush
Joints Preparation - Use Compressor & blow pipe
Roller Pattern to be determined by this Site Paving Trial Section
Compaction of Asphalt Roller Pattern - Temp 121*C to 160*C
Aim - to achieve target density and smoothness of surface
Procedure :- Initial or Breakdown Rolling Intermediate Rolling Finish Rolling
In advance
1 Establish Mix design by Shell and carry out Tests
2 Prepare Paving Trial Area
3 Decide on Rolling Pattern Roller type : Steel Tandem RTR Steel Tandem
4 Clean surface
Pneumatic Tyre Roller
5 Spray Prime coat Make & model : BW 161 AD-4 BW 25 RH BW 161 AD-4
At time of Trial # of Rollers 1 # per 7.5m strip 1 # per 7.5m strip 1 # per 2 x 7.5m strips
Asphalt Base-course Mix Design Details 6 Lay asphalt as per details contained on this chart # of Passes : 2 # 3 # 3 #
7 Carry out compaction as per rolling pattern as opposite Vib / Static : 1 # Vib pass & 1 # Static Static Static
Probably one Months time by Shell 8 Carry out tests for levels, smoothness, compaction, temperature and layer thickness Weight ballasted 25 tonne 10 tonne
Post Trial Speed : 5 Km/hr 4.5Km/hr 8 Km/hr
9 Carry out laboratory Tests as per ITP. Tyre Pressure : Pass is "one coverage" by the roller in one direction
10 Prepare report on Trial with test results Pneumatic Tyre Roller (PTR) used to knead the mix and achieve most compaction.
10 tonne
60 lbs/in
Prime Coat - apply by distributer lorry with spray bar @ 90 degrees & allow to cure within
24 to 48 hours
2 # Pavers in Echelon
Pavement Construction
Procedure for Carrying out PmB Asphalt Paving Trial
for Base-course for Runway & Taxiways
Purpose of Asphalt Pavement Trial :- To demonstrate that asphalt can be lay and compacted on
site that meet all requirements of the specification. Also to establish rolling pattern
Roller Pattern to be determined by Compaction Test Strip for checking density & smoothness,
detailing sequence of rollers, # of passes, speed of rollers and vibratory or static passes.
Following day complete paving this area to demonstrate
cold joint work
Page 16 of 87

Muscat Airport Expansion David Moloney 1/10/2010
Ref Method Statement # 29
Asphalt Batching Plant Yard On-Site Aggregate sizes - 0-4mm, 4-12mm, 12-19mm & 19-25mm
References
Specification Series 400 Bitumen Pavements
QA/QC ITP for Bituminous Pavement Activities SE-CTJ-01CW-PLN-00004
ITP Aggregates for Asphalt Production SE-CTJ-01CW-PLN-0006
Method Statement # SE-CTJ-01CW-MST-00029
Marini Asphalt Batching plant
Model - Top TOWER 4000 P Tests to be carried out
Plant Capacity - 300 tonnes per hour Aggregates for Asphalt Production see ITP SE-CTJ-01CW-PLN-0006 Rev 2
Mixer Batch Capacity - 3.5 tonnes Pavement Activities see ITP SE-CTJ-01CW-PLN-0004 Rev 3
250 tonne with 4 # screens
3 Filler Silos ( 2 for imported, 1 reclaimed)
Fibre Feed System
Wibau Asphalt Batching plant Asphalt Yard Layout
Plant Capacity - 180 tonnes per hour
Mixer model - WKM 250-4
2 Filler Silos ( 1 for imported, 1 reclaimed) Schematic showing Batching Plant Operation
Production Rates, Storage & Consumption of Materials
Production rates. Temperatures Heating system Cut-off
Both Batching Plants Outputs 450 t/hr 4,500 t/10hr day Storage of Bitumen 155*C
Mixing PmB on site 15 t/hr 360 t/ 24hr day PmB 150 - 160*C
Mixing
Consumption Rates Aggregates in Dryer
Aggregates 450 t/hr 4,500 t/10hr shift Mix design Approximate
Bitumen 60/70 (4.8% ) 25.5 t/hr 255 t/10hr shift Aggregates
Polymer (3.8kgs / t) 1.7 t/hr 17 t/10hr shift 0 to 5mm 45 to 50%
PmB 27.2 t/hr 272 t/10hr shift 5 to 10mm 28 to 30% 92%
Diesel for Dryer ( 5 ltrs / tonne) 2,250 ltrs/hr 22,500ltrs /10hr shift 10 to 19mm 20 to 27%
Storage Capacities Binder for wearing course approx 4.8%
Aggregates Stockpiles 5,400 tonnes 2 weeks stockpile
Bitumen 60/70 (4.8% ) 650 tonnes Fillers imported 2%
Polymer (3.8kgs / t) Delivered in 400t consignments Fillers from Baghouse 2%
PmB ( Polymer & Bitumen mixed ) 200 tonnes
Diesel ( For Dryer 5 ltrs /t of aggregate ) 2 x 50,000 litres Tanks PmB Blending Plant
Mixes & Quantities Calibration Schedule Frequency Massenza Plant
Quantities Ingredients Weigh Bridge Yearly
Asphalt Concrete - Wearing Course (ACWC) 136,000 m3 Aggregates, mineral fillers, Bitumen 60/70, Polymer, anti stripping agents Weigh Box in Batching Tower Yearly
Asphalt Concrete - Binder Course (ACBC 1) 83,000 m3 Aggregates, mineral fillers, Bitumen 60/70, Polymer, anti stripping agents Bitumen Flow gauges Yearly
Asphalt Concrete - Base Course (ACBC 2) 270,000 m3 Aggregates, mineral fillers, Bitumen 60/70, Polymer, anti stripping agents
Stone Mastic Asphalt ( SMA) Bridge Decks xxx m3 Aggregates, mineral fillers, Bitumen 60/70, Fibres, anti stripping agents
Asphalt Sand Carpet ( Bridges) xxx m3 Sand, Bitumen 60/70 Wastage
Daily Material Reconciliations to be recorded
Notes RAPs Reclained Asphalt Pavements will not be used in any of the above mixes
Notes on Operation
Prime & Tack Coat Production MS # 153 Lorries will be filled through hot storage bins to achieve continuity of operation
Pavement Trial on site will determine final temperatures and mix designs.
Dust Subpression - Keep roads damp
PmB (Polymer Modified Bitumen) Production MS # 127
Living Document for Discussion
Prime Coat - MC 70 , Bitumen 60/70 - 57 % minimum as per ASTM D-977, CPB/L 1.5 % , Water - balance towards 100 %, Total Emulsion 100
%, Kerosene - 130 litres for 1000 litres of Prime Coat
Tack coat - SS-1, Bitumen 60/70 - 57 % as per ASTM D-977, Caustic Soda 0.15 -0.2 % for powder NaoH, Iteral AL-98/N 0.15%, Interpitch B - 0.85%, + Water
balance towards 100%, Total Emulsion 100%
The PmB blend is that of 60/70 straight run bitumen, (supplied from 10 base bitumen tanks), and butadiene-styrene copolymer, Commercial name Calprene 411 or LG-
411 elastomers.
Page 17 of 87

C:UsersUserDesktopMuscat Runway Constructionc11e PmB Asphalt Chart Testing -
References Method Statements
SE-CTJ-01CW-MST-00137
ITP
Muscat Airport Expansion Photos showing tests SE-CTJ-01CW-PLN-00057
Hardness of bitumen at a certain
temperature usually 25*C
Expressed in 1/10mm
Usual range 10-250 1/10mm
Ring and Ball Temperature
- Temperature at which the bitumen
softens ( also softening point)
Expresed in *C
- Usual range 30 to 120*C
Determine
- viscosity at 135*C
- viscosity at 165*C
Purpose
- check for handling and pumping
- develop temperature / viscosity relationship
- determine mixing and compaction temperature
Test :- Penetration test Test :-Softening Point (TR&B) Test :-Dynamic Viscosity
Test :-DSR on Original binder, RTFO aged binder,
RTFO + PAV aged binder
Test Method :- AASHTO T49 Test Method :- AASHTO T53 Test Method :- AASHTO T316 Test Method :- AASHTO T315
Location:- SP-1 Lab at DMIA site Location:- SP-1 Lab at DMIA site Location:- SP-1 Lab at DMIA site Location:- SP-1 Lab at DMIA site
Simulate short term aging during asphalt mix
production
Simulate long term aging during
pavement service life. This is only a
conditioning step for intermediate and
low temp evaluations.
This is another conditioning step to
release the entrapped air during PAV
conditioning.
Test :- Rolling Thin Film Oven Test (RTFOT) Test :-Pressure Aging Vessel (PAV) Test :-Vacuum Degassing Oven
Test :-Stiffness & m-value measure in BBR on
RTFO + PAV aged binder
Test Method :- AASHTO T240 Test Method :- AASHTO R28 Test Method :- AASHTO R28 Test Method :- AASHTO T313
Location:- SP-1 Lab at DMIA site Location:- SP-1 Lab at DMIA site Location:- SP-1 Lab at DMIA site Location:- SP-1 Lab at DMIA site
Compiled by Dr B MANOJ, Sr. Technical Engineer, CCC TAV-JV
Polymer Modified Bitumen ( PG 76-22)Testing
1
6
3
C
Page 18 of 87

C:UsersUserDesktopMuscat Runway Constructionc11f Asphalt Tests Chart -
Chart showing Tests References
Method Statements
Muscat Airport Expansion For inclusion in Factual Report ITP
Mahmoud AbdulBaki 8th June 2011 SE-CTJ-01CW-PLN-00006
The maximum theoretical density (or Rice
Density) is the unit weight of the mix if it were
compacted so it contained no air voids.
TEST & PURPOSE :- Rice Density Test is a
test to compute the Maximum Specific Gravity
(Gmm) of Asphalt
TEST & PURPOSE :- Tensile Strength of
asphalt generally and across joints
TEST & PURPOSE :- Compaction by
testing cores from site
TEST & PURPOSE :- Thickness by
measuring cores from site
TEST & PURPOSE :- Hamburg Wheel
tracking Test. Use this test method to
determine the premature failure susceptibility
of bituminous
Tolerance :- For joints 80% on general
Tolerance:- Min 94% of Maximum Specific
Gravity Gmm
Tolerance:- Reguired thickness -5mm Tolerance:-
Location:- On-site Laboratory Location:- On-site Laboratory Location:- On-site Laboratory Location:- On-site Laboratory Location:- On-site Laboratory
Metal beam 3 mt. long suspended by two legs at the
extremities. Along with two graduated wedges for
measuring
.
TEST & PURPOSE :- Extraction(Bitumen
content & Gradation) to measure
ingredients
TEST & PURPOSE :- Compaction by Cores
TEST & PURPOSE :- Smoothness by
straight edge and measuring gap underneath
in middle
TEST & PURPOSE :- Engineers Level &
Staff used to take levels
TEST & PURPOSE :- Temperature by digital
therometer
Tolerance :- +/- %
Tolerance:- Min 94% of Maximum Specific
Gravity Gmm ie the maximum theoretical
density (or Rice Density)
Tolerance:- Max 6mm with 3m straight edge Tolerance:- +/- 6mm tolerance :- Varies
Location:- On-site Laboratory Location:- On-site Location:- On-site Location:- On-site Location:- Batching Yard & On-site
1
Pavement Trial - Asphalt PmB Basecourse Testing Sheet 1 of 2
Page 19 of 87

Prime & Tack Coat for Asphalt
On-site Production Prime Coat Tack Coat
MC = Medium Cure SS = Slow Set
References Details Details
Specification :- SE-CWL-SPC-11104-F Material :- MC 70 Cationic Bitumen Emulsion Material :- CSS-1h
Method Statement :- SE-CWL-01CW-MST-00153 Description :- Bitumen in a Kerosene medium Description :- Bitumen in a Water medium
Ingredients Rate of Application :- Target 0.50kgs/m2 Rate of Application :- Target 0.230 kgs/m2
o Bitumen 60/70 Temperature of Application :- 90*C +/- 5*C Temperature :- Minimum 30*C or ambient Temp
o Kerosene Bitumen - Penetration Grade of (Bitumen 60/70
o Caustic Soda
o Water
o Emulsifier for Prime References References
o Emulsifier for tack
Specification :- Specification :- Series 400 Bituminous Pavement
Clause 401
I.T.P. SE-CWL-01CW-PLN-0006 I.T.P. SE-CWL-01CW-PLN-0006
Process
Site Trial Factual Report :- SE-CWL-01CW-REP-16006 Site Trial Factual Report :- SE-CWL-01CW-REP-16037
Method Statement :- SE-CWL-01CW-MST-00040 Method Statement :- SE-CWL-01CW-MST-00040
Material Approval :- MAT - 00296 Material Approval :- MAT - 00259
Plant Plant
Lorry mounted Sprayer - Phoenix Model FC 8000 Lorry mounted Sprayer - Phoenix Model FC 8000
MC 70 by Horizon
Purpose :- Applied to Asphalt courses to provide bond for
next asphalt course
Purpose :- Applied to an aggregate surface to seal the surface and provide a
bond for the asphalr course to be laid on top
a. Water will be pumped from the storage tank and heated.
d. The bitumen and water solution are now mixed and visually
inspected.
b. When the water has reached the required temperature the
caustic soda will be added to reach the required ph value of between
11 and 12, the caustic soda and water will be mixed for about 5
minutes to reach a homogeneous ph solution.
c. The emulsifiers are added to the water and caustic soda
solution
Series 400 Bituminous Pavement
Clause 401
CSS-1H by Cy Tech
Page 20 of 87

Specification Requirements Level Control
Concrete PQ ( Pavement Quality) Stringlines & sensors
David H Moloney 19th June 2011 Mix :- 50N40 w/c ratio 0.42% 25mm slump Finish :- Brush Level Equipment
Curing by :- Initial by curing agent then moist hessian & plastic sheeting for 14 days 2 # stringlines
Protection :- Keep traffic and pedestrians off slabs for 14 days Pins set at 5m centres with wire 350mm over ground level
Combines "Lessons Learned" at Doha Airport Separation Membrane :- Plastic Sheeting Paver with autonated level control , sensoring two stringlines
References - Joints Level Tolerances
1 Method Statement # 31 Expansion @ 50m c/c Surface +/- 10mm Concrete Batching Plants
2 Specification Series 5100 Pavement Concrete Contraction @ 5 m c/c Under Straight edge 3 m long. 3mm on slabs & 5mm across slabs Liebherr Mixer 2# 37m3 per hour each
3 ITP SE-CTJ-01CW-PLN-0008 Longitudinal @ 5m c/c Slab Thickness NACE Mixer 1# 43m3 per hr
4 Drawings SE-CTJ-CWCA-X-12000X-63011 Sealant for concrete joints - Cold applied Polyurethane or polysulphide Not less than designed thickness by 15mm on average Above based on 90 second mixing times
Materials Approval Submissions Sealant for concrete to asphalt joints - Hot applied
Temperatures :- Fresh max 32*C, during hardening max 65*C
Sun's Rays Protection :-
Wastage & Efficiency Cover with canvas shade set 300 high
Tipper Lorries
3 axles, 8m3
Vibrator fitted to aid discharge
Slab Thicknesses
Runway & Aprons = 450mnm
Stands & Isolation Bays = 390mm
Fuel Farm = 250mm
Gomaco Placer / Spreader
Testing Train of Plant Gomaco Slipform Paver GP-2600
Consistence by slump cone Delivery :- Tipper lorries
Section thru Pavement Compressive strength by Cubes Placer :- Gomaco Placer / Spreader with side conveyor
Levels by Engineers level Slipform Machine:- Gomaco GP-2600
Smoothness by Straight Edge Touch up :- Off foot bridge on wheels
Plastic separation membrane placed on Cement Stabilised Base Course CSBC Ingredients by Sample to Lab Brush :- Gomaco Texturing Machine
Spray Bitumen coat, better than plastic sheet as paver will tear it. Quantities, Outputs & Durations Texture depth by Sand patch method Curing :- Spray off foot bridge on wheels
Quantities Cutting Joints :- Saw cut contraction joints within 10 hours
Lorry Round-trip Cycle Time Slabs for Runways & Taxiways = 12,400 m3 Dowel drilling :- Drilling Rig
Travel from batching plant to site Av 5km 10 minutes Aprons & Aircraft Stands = 127,200 m3
Queue, Reverse, Unload & Pull out 3 to 5 minutes TOTAL = 140,000 m3
Return to batching plant 10 minutes Materials Typical Crew Gomaco Texturing Machine
Mix & Load 10 minutes Output per Day (10 hrs shift) 7 # by 45 m long strips = 700 m3 / day Concrete 50N40 25mm slump Engineer
Total 40 minutes => 200 days Curing Agent - Concure by Fosroc Supervisor
=> 8 # Lorries with capacity 8m3 required Slipform - Outputs & Pave Speed Joint Sealant Slilform Operator
Rate of Pour = 100 m3 per hour Concrete Mix Details 25mm slump Hot - Igas-K by Sika Labourer
Sequence of Construction :- Volume per metre run = 2.25 m3 per metre run 50N40 with < 40 mm slump. Temp <32*C Cold - Colpor by Fosroc Banksman
Hit and Miss strips Linear metres per Hour = 45 linear metres per 60 minutes 410 kgs Cement Joint Filler Hydrocell by Fosroc Breaks for meals 30 minutes maximum
Hand lay stop ends with shutter & return ends Rate of Pave = 0.75 linear metres per minute 745 kgs Washed Natural Sand Anchor Grout for Dowels Lokfix by Fosroc
Formwork at start 320 kgs 10mm Crusher Agg
Alternative put a stop end in 0.75m past the original line and deep saw at a later date, 450 kgs 20mm Crusher Agg Saw Contraction joints
Jump Bay at expansion joints 480 kgs 40mm Crusher Agg within 10 hours
154 kgs Water
Sequence of Construction Photos Note :- Position of ground lights relative to slab joints to be looked at. 4.5 ltrs Rheobuild 857
Sealing Joints hot sealant
Dowel Cage 5m x 5m x 0.45m concrete pavement Slab
Dowels & Tie-bar
Placer with side conveyor Slipform Paver Float at back Foot bridge Texturing Machine Foot Bridge 40 mm dia coated for Contraction & Expansion Joints
Step 1 Step 2 Step 3 Step 4 Step 5 16 mm dia for Longitudinal joint with Key ( Tie joint)
Unload place, spread, strike off Vibrate, Screed & Float Touch up Brush Finish Curing by spray Note expansion joints dowels to have caps
& Final touch up Dowels preassembled in cages for contraction joints Dowels Drilling Rig
Note - No reinforcement in slabs 500 # holes per day per Rig
Telescopic Frames 3.66 m to 9.75 m
Cost
Controls.
Save
concrete
by
keeping
the
layer
of
cheaper
material
underneath
on
the
high
side
of
the
allowable
tolerance.
Carry
out
daily
material
reconciliations
on
the
material
used
against
the
quanity
that
will
be
paid
under
the
contract.
Record
the
daily
waste
factor
and
seek
ways
to
reduce
waste
and
improve
output.
60 # persons
Material Waste - Keep tight control by reconciling daily the quantity of concrete used on
site, against quantity that will be paid to establish the daily waste factors.
Ensure level of cheaper aggregate layer under is not low. As the daily crew cost if fixed,
seek ways to improve the daily output without compromising quality.
Concrete Pavement by Slipform
Page 22 of 87

Concrete Batching Yard On-Site Concrete Mixing Plant ( TAV)
Maufacturer :- NACE
Muscat Airport Expansion References Model :- MC14
David Moloney 13th Nov 2011 Method Statements # 16 Type :- Twin Shaft
Chilled Water Tanks Mixer Capacity :- 2.25 m3
Hot Weather Measures Outputs
Aggregate Bays covered with Sunshades With a 45 Seconds Mixing Time
Pre chilled water Hourly output:- 43 m3 /hr
Ice Flakes added to mix water Water Tanks Storage for Site Ice Flake Plants 32 t per day each ( Manufacturer - KTI )
Silos & Mixer trucks painted white ( Evaporator, Ice Making Machine & Ice flake store)
Night pours
Minimise delivery time to site Wet Mix Macadam Mixing Plant Capacity 120m3 per hour
continuous mixing
4# aggregate bins, Pugmill mixer
& storage / discharge hopper
NACE Mixer Plant - Twin Shaft 2.25m3
Wash Out Pit
& Settlement Tanks
Incidental Plant
Truckmixers ( Drum 8 to 9 m3) 20 #
Concrete pumps 32m boom (50 m3 / hr) 4 #
Loading shovels (Bucket 2m3) 2 #
Aggregate Storage Bays
14 Bays 10m x 30m x 2.5m high
Yard Managers Office
Concrete Mixing Plants ( CCC)
Liebherr Mixer NACE Mixer Maufacturer :- Liebherr
Mixer capacity 2.25 m3 2.25 m3 Model :- Betomix 2.25 A-R / RIM
Cement Silo 1# 500 tonne 5# 100 tonne Type :- Pan Mixer
& 2# 200 tonne Mixer Capacity :- 2.25 m3
Fly Ash Silo 1# 200 tonne 1# 30 tonne Outputs
Microsilica Silo 1# 30 tonne 1 # 30 tonne With a 45 Second Mixing Time
Hourly output:- 27 m3 /hr
Ice Flake Plant 1# 42 t/day 1# 32 t/day
Laboratory & Offices Liebherr Betomix 2.25m3 Mixing Plants - Pan mixers
Water is also cooled by 3 *C using Chillers & stored in insulated tanks 10,000 gallon capacity
Note - Ice flakes will be added to the mix to pre-cool the
concrete, 10 kgs of ice flake will reduce the temperature of
concrete by approx 1.3*C per m3.
Dune Sand 2mm, Washed sand 4mm,
Aggregates 40, 20, 10mm
Page 23 of 87

C:UsersUserDesktopMuscat Runway Constructionc12c APC Tests Chart -
Chart showing Tests References
Method Statements
Muscat Airport Expansion For inclusion in Trial Procedure ITP
David 8th June 2011 SE-CTJ-01CW-PLN-00011 & 12
TEST & PURPOSE :- Consistency by Slump
cone
TEST & PURPOSE :- Cube testing for
Compressive Strength Development
TEST & PURPOS :- Flexural Strength
Development. By beams
TEST & PURPOSE :- Temperature
Development
TEST & PURPOSE :- Thickness
Tolerance :- Max. allowable deviation on
target value +/- ⅓ + 10mm
Tolerance :- Min 50N Tolerance :- Min 5.0 Mpa
Tolerance:- The temperature shall be measured in the
middle of the slab vertically. Reading for 3 days at 8hrs
intervals
Tolerance:- Not less that 25mm from design & verage
of the three cores shall not be less than the design
thickness less 15mm
Location:- On-site Location:- On-site Laboratory Location:- On-site Laboratory Location:- On-site Location:- On-site
TEST & PURPOSE :- Density of Hardened
Concrete by Crushing Cubes & Cores
TEST & PURPOSE :- Sand Patch Texture
TEST & PURPOSE :- Smoothness by straight
edge and measuring gap underneath in
middle
TEST & PURPOSE :- Engineers Level & Staff
used to take levels
TEST & PURPOSE :- Temperature by digital
therometer
Tolerance :- Cube min 50N, Cores min 40N
Tolerance:- Texture depth shall be
minimum1.0 mm and no single values shall be
less than 0.6 mm.
Tolerance:- ±3 mm in slab middle and ±5 mm
across joints.
Tolerance:- +/- 10mm from the design
elevations.
Tolerance :- Max 32*C
Location:- On-site Laboratory Location:- On-site Location:- On-site Location:- On-site Location:- Batching Yard & On-site
Airfield Pavement Concrete Testing
Concrete 50N40: Machine-lay work < 40 mm slump & for hand-lay work 50 to 90 mm slump.
Page 24 of 87

Airfield Pavement Marking
Page 25 of 87

David H Moloney
Inset Runway Lighting & Elevate Approach Lighing Inset Light & Pot Layout of Trenches Cross Section of Inset Ground Light
Cutting Trench for Ducts Placing Ducts Manhole Precast Bachfilling Trench with Concrete
Core Drilling for Inset Light Removing Core Fixing inset ground light Placing Cables in ducts
Approach Lights - Elevated Approach Lights - Elevated Electrical Sub-Station Electrical Sub-Station
o
Airfield Ground Lights - AGL
Page 26 of 87

Runway Approach Lighting
Page 27 of 87

Airport ILS & Signage
Glide Slope Indicator Localizer Calibration Flight
Frangible posts are designed to break away cleanly upon impact, minimizing damage to an aircraft during an accident.
Page 28 of 87

C:UsersUserDesktopMuscat Runway Constructionc16 Airside Safety for Contractors POSTER
Contractor :- ABC plc
Date :- May 2021
Project :- ABC Contract
By :- David H Moloney
Aim of this Poster to to bring to the attentions of the workforce the issues in a straighforward and easily understood way. Print A3 or A2 size.
aims to create an Irish society where everyone can enjoy
1
1 1 1
Cause - Pumping & run-off
Settlement Pond & Filter Drain
Filter Drain
Stream / River
Preventative Measures Measures Measures Preventative Measures
1 1 1 1
2 2 2
3 3 2
Airport Security
Aviation security is a combination of
measures and human and material
resources in order to safeguard civil
aviation against acts of unlawful
interference. Unlawful interference could be
acts of terrorism, sabotage, threat to life
and property, communication of false
threat, bombing, etc.
Airport Security
Report any suspicious activities or persons
Only discharge silty water into designated
settlement systems or onto grassland.
Reclamation of waste at source with
recycling.
Record waste details according to
consignment record system to ensure
compliance regulations
Source - Used oil/fuel filters, waste oil, used
batteries, solvent and thinners, paint wastes,
asphalt road planings etc.
Usage of Alternative 'ECO Friendly'
Substances, Reduce or Substitute.
All hazardous waste shall be
appropriately packed, labeled
Hazardous waste shall be disposed at
licensed treatment or disposal sites
only.
Don’t pump silty water directly into rivers,
ditches or surface water drains.
Designated vehicle wash areas
Sheeting vehicles carrying dusty
materials to prevent materials being
blown from the vehicle whilst travelling
Cause - Blown from the vehicle whilst travelling
Air Pollution - Dust
Waste Hazardous
Organization, Responsibilities & Supervision
Project Director: Overall responsibility for the project
operations and activities in a manner to ensure attaining the
project objectives.
HSSE Manager: Responsible for ensuring that all the project
activities are performed in an appropriate manner fulfilling the
project health, safety and environmental requirements.
Safety Officer, responsibe for: Toolbox talks, Implimentation
of Method statements, Training of workforce, provide safe
system of work and comploance with safety procedures
Site Engineer/ Site Superintendent: Responsible to ensure
that the construction of the Common water supply is in
accordance with the current issue of construction, shop
drawings, method statements and specifications
Land Surveyor Responsible to set out the lines and reference
benchmarks which should assist the erection crew during
construction. All setting out works will be based on current
issues of construction/ shop drawings.
General Foreman: Responsible for executions of works as
per the method statement
Health, Safety, Security & Environment for Airside Construction
Training
Site Induction
Toolbox Talks
Training Matrix
Tracking HSSE Issues
Use Dashboard Monthly
Dedicated
Recycling Skips
Ground Water Pollution
References
Contractor's Documents
1. Health, Safety &Environment Plan
2. Method Statements - various
3. Risk Assessments
4. Airside Specific Documents
a. Method of Work Plan
b. Risk Assessments
ICAO Documents
1 ICAO's Annex 14 Volume1 Aerodromes Design &
Operations FOD can cause damage in a number of
ways, the most notable being:
- Damaging aircraft engines if ingested;
- Cutting aircraft tyres;
- Lodging in aircraft mechanisms
preventing them from operating properly;
- Injuring people afer being propelled by a
jet blast or prop wash.
the “obstacle limitation surfaces” define the
limits to which objects may project vertically
into the airspace surrounding an aerodrome
so as to permit aircraft to be operated
safely.
Bird strike is a collision between an
airborne animal and are a significant threat
to flight safety, and have caused a number
of accidents with human casualties. Donts
attract brirds by feeding them or leaving
waste food around
COSHH is the law that requires employers
to control substances that are hazardous to
health. Aim is to prevent or reduce workers
exposure to hazardous substances
E
N
V
I
R
O
N
M
E
N
T
The aim is to create a site where
everyone can enjoy physical and
mental health, and where wellbeing is
valued and supported at every level.
The objective of workplace safety is to
help prevent workplace injuries,
illnesses, fatalities and damage to
property. To carry out Risk
assessments to identify Hazards and
establish control measures to reduce
risks. To provide guidance in the event
of an accident, fire, natural disaster or
other emergency.
The aim of aviation security is to
prevent acts of unlawful interference,
above all by keeping threatening items
such as arms and explosives away
from aircraft.
Environmental protection is the
practice of protecting the natural
environment. Its objectives are
to conserve natural resources and the
existing natural environment and,
where possible, to repair damage and
reverse trends.
H
e
a
l
t
h
S
A
F
E
T
Y
S
E
C
U
R
I
T
Y
Personal Protective Equipment
Security Pass Security Screening
PPE will protect the user against health
or safety risks at work. E.g safety
helmets, gloves, eye protection, high-
visibility clothing, safety footwear and
safety harnesses. respiratory protective
equipment (RPE).
Safety Training
To provide the workforce with knowledge
and skills to perform their work in a way
that is safe for them and their co-workers.
Restricted Airspace Foreign Object Debris (FOD)
Waste Non-hazardous
Equipment will be subject to x-ray
screening when going through security.
Persons will be scanned. The scanner
software recognizes metallic and non-
metallic items hiding under clothing.
Applicants will be vetted for criminal
records. Security pass must be worn when
airside
Bird strikes
Substances Hazardous to Health Jet Noise
Jet Blast
Can blow over ground equipment
(baggage carts, aircraft steps, vehicles,
etc.), cause structural damage to buildings,
or injure or kill passengers, crew and
ground personnel
Jet noise is also responsible for some of
the loudest sounds ever produced by
mankind.
Wear hearing protectors when engaged in
work that exposes you to noise
Flow
Page 29 of 87

Contractor - ABC Ltd Year-_____________
Project - Runway Month - ___________
Calendar with calendar week numbers.
Week Nr 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
Month
Week
Commencing
Monday
Mon
4th
Jan
Mon
11th
Jan
Mon
18th
Jan
Mon
25th
Jan
Mon
1st
Feb
Mon
8th
Feb
Mon
15th
Feb
Mon
22nd
Feb
Mon
1st
Mar
Mon
8th
Mar
Mon
15th
Mar
Mon
22nd
Mar
Mon
29th
Mar
Mon
5th
Apr
Mon
12th
Apr
Mon
19th
Apr
Mon
26th
Apr
Mon
3rd
May
Mon
10th
May
Mon
17th
May
Mon
24th
May
Mon
31st
May
Mon
7th
Jun
Mon
14th
Jun
Mon
21st
Jun
Mon
28th
Jun
Mon
5th
July
Mon
12th
July
Mon
19th
July
Mon
26th
July
Mon
2nd
Aug
Mon
9th
Aug
Mon
16th
Aug
Mon
23rd
Aug
Mon
30th
Aug
Mon
6th
Sept
Mon
13th
Sept
Mon
20th
Sept
Mon
27th
Sept
Mon
4th
Oct
Mon
11th
Oct
Mon
18th
Oct
Mon
25th
Oct
Mon
1st
Nov
Mon
8th
Nov
Mon
15th
Nov
Mon
22nd
Nov
Mon
29th
Nov
Mon
6th
Dec
Mon
13th
Dec
Mon
20th
Dec
Mon
27th
Dec
Manpower Histogram Plant & Equipment HSE Statistics Board
Histogram for Asphalt Laid Contacts Database for Staff Document Submissions
Method Statements Risk Assessment
COSHH Sheets i.e. Control of Substances Hazardous to Health
Shop Drawings
Material Approval Sheets (MAS)
Inspection and Test Plans
QA & QC Plan
Programme
Progress Photos
Pavement Markings Asphalt Laydown Approach Lighting Taxiway Signage Security Fencing Temporary Gateway Temporary Fencing Temporary Fencing
Dashboard to Track Progress & Safety
July 2021 August 2021 September 2021 Octomber 2021 December 2021
November 2021
June 2021
January 2021 February 2021 March 2021 April 2021 May 2021
Page 30 of 87

C:UsersUserDesktopMuscat Runway Constructionc17a Environmental Awareness
David H Moloney May 2021
Cause - Washing Machines
Cause - Pumping & run-off
Settlement Pond & Filter Drain Earthworks
Drip Tray Nozzel Auto shut-off
Pond Filter Drain
Wheelie Bin 205 ltr Drum
Preventative Measures Stream / River
Preventative Measures 1 Use funnels when fuelling from containers Preventative Measures Preventative Measures Preventative Measures
1 2 1 1
Preventative Measures
1
2 3 2 1 2
3 Provide drums with lids for waste oil & filters
4 2 2 3
4 5 3 4
Waste Non-hazardous Waste Hazardous Mud Pollution on Public Roads Air Pollution - Dust Air Pollution - Dust Air Pollution - Emissions
Lorry Wheel Wash
Measures Measures Preventative Measures Preventative Measures Preventative Measures Preventative Measures
1 1 1 1 1 1
Those Responsible
2 2 2 2 2 2
Senior Project Manager
HSE Manager
3 3 3 3 3
Environmental Staff
k
Construction Manager
Machinery Noise Manage Noxious Weeds Manage Non-Native Invasive Plants Archaeology Protected Species - Badgers
Training
Use Toolbox talks
Use this Poster
Preventative Measures Preventative Measures Preventative Measures Measures Measures
1 1 1 1 1
2 2 2
3 3
u
To cut down on the amount
of waste we throw away
It is illegal to carry out any construction
work close to a badger sett without taking
steps to positively avoid damage.
Don’t obstruct the access to, or any
entrance of, a badger sett.
IMMEDIATELY stop work and inform your
line manager if you discover a badger sett
or see a badger on your site.
Don’t interfere with a badger sett by
damaging or destroying it
Dedicated Recycling Skips
Environmental Protection & Awareness - Training POSTER
Cause - Blown from the vehicle whilst
travelling
Sheeting vehicles carrying dusty materials
to prevent materials being blown from the
vehicle whilst travelling
Designated vehicle wash areas
Enforcing low speed limits for vehicles on
unmade surfaces minimizing the
generation of airborne dust
Japanese Knotweed it grows rapidly and
forms dense clumps over 3m high
Cause - the Storage of Fuel & Oil and
Waste Oil & Filters
Refuel, service and store oil away from
watercourses or surface water drains.
IMMEDIATELY stop all work within 7
metres of the suspect plant and contact
your line manager for instructions if you
think you have identified Japanese
Knotweed on your site.
Archaeology is the study of human history
through the excavation of sites and the
analysis of physical remains.
Stop work if you find any archaeological
features and immediately contact your
manager for instructions 9 Obey the
advice provided by any appointed
archaeologist.
Construction Pollutants to Surface and
Ground Water, include pumped water to
keep excavations dry, water runoff caused
by rain and storms
Construction Pollutants to Land, include
Waste materials generated during
construction
Pollution is the introduction of harmful
materials into the environment. These
harmful materials are called pollutants.
Pollutants are created by construction,
damage the quality of air, rain water, and
land.
Construction Pollutants to AIR, include
dust generated from various construction
activities, earthmoving and emissions from
various light vehicles and diesel or petrol
driven equipment.
Site Documents the Construction
Environmental Management Plan states
how the contractor will manage and
minimise negative effects during
construction.
Regular water spraying of unpaved and
sweeping of paved roads to minimize dust
and remove mud
Ready-mix trucks to washout in areas
designated for the purpose.
Ambient air quality survey is conducted
Source - Offcuts, Packing, Surplus, Office
Waste.
Waste oil & filters - sent to a Waste
Management Company
Use of only modern, well maintained
machinery to minimize mobile source
emissions
Maintenance of plant & equipment to
prevent excessive exhaust fumes
Divert any surface water flows away from
traffic areas.
Cause - Lorries carrying mud on their
tyres onto public roads
Usage of Alternative 'ECO Friendly'
Substances, Reduce or Substitute.
Ensure that any wash down slurry or
residue is contained and cannot enter
drains or watercourses
Reducing the quantity of dusty materials
stored on site or covering stored material
Only strip land of vegetation it it is
absolutely necessary as vegetation
reduces silt run-off.
Source - Used oil/fuel filters, waste oil,
used batteries, solvent and thinners, paint
wastes, asphalt road planings etc.
Land & Surface / Ground Water
Pollution
Cause - Concrete Washout from lorries
and pumps
Pollution
Pollution
Pollution
Don’t pump silty water directly into rivers,
ditches or surface water drains.
Use drip trays where nuisance leaks and
drips may occur.
Keep a spill kit near to fuel and oil storage
areas and refuelling areas.
Store oils away from drains or
watercourses
Keep a spill kit near to fuel and oil storage
areas and refuelling areas.
Cause - Rainwater run-off from
uncovered areas of the site
Cause - Fuelling & Servicing Machines
Pollution
Pollution
Filter drains have straw bales,
geotextile & 20 mm clean stone.
Provide settlement systems for water run-
off.
Only discharge silty water into designated
settlement systems or onto grassland.
Cause - Dust from earth moving
operations and traffic movements to and
from site.
Cause - Toxic Emissions from machiney
exhauses
Store soil away from watercourses or
drains.
Example - Ragwort,
Washout water not to flow into any
watercourse or drain.
Use Fuel Nozzel that automatically shuts-
off the flow of fuel when vehicle tank is full.
Use the minimum amount of water to
reduce waste.
Install Wheel Washing Facility provided
with high-pressure hosing before leaving
the site
Ensure hose down spills of concrete or
cement don’t flow into surface water
drains.
Vehicles going from the work site onto
paved roads must be free of excessive
mud.
Plant & equipment is maintained to prevent
excessive noise emissions and silencers
fitted where possible.
Ensure that plant and equipment is free of
soil / weeds prior to being brought to site
Reclamation of waste at source with recycling.
Record waste details according to consignment
record system to ensure compliance regulations
Cause - Construction noise levels
associated with sources such as
excavators, lorries, dump trucks,
compressors, etc.
Operators should be provided with ear
muffs
Noxious weeds will be recorded during pre-
construction surveys conducted by the
project ecologist
The plant must be fully and continuously
suppressed and destroyed.
Hazardous waste shall be disposed at
licensed treatment or disposal sites only.
All hazardous waste shall be appropriately
packed, labeled and shall have a waste
consignment note when transported out.
Waste
Waste
Flow
Typical Cut to Fill Situation
Cut
Fill
Page 31 of 87

David H Moloney
Trench with Sloping Faces Trench with stepped Faces
Trench with Shoring System Barricades with signs to prevent people and plant
getting near the excavation
Underground Utility Colour Code Underground cable location equipment / cable
avoidance equipment
Mark location and route of underground utilities on the
surface prior to excavation
Acccess down into and across the excavation
Photo shows Excavation with Sloping Faces Photo shows Excavation with Stepped Faces
Excavation on Street with numerous underground
Utilities
Excavation on street with underground utilities
temporiarly supported
Excavation Safety Measures
Excavation, Underground Utilities & Overhead Cables
Page 32 of 87

Contractor :- Date :
Contract :- Doc Ref :-
In-House
SPECIALIZED
COURSES
Manual
Handling
Work
at
Height
Rigging
&
Lifting
Confined
Space
Excavation
Flagman
/
Banksman
Scaffolding
Heat
Stress
Housekeeping
Waste
management
Risk
Assessment
Safety
Leadership
&
Management
Accident
Investigation
&
Reporting
Job
Safety
Task
Instruction
Portable
Power
Tools
Grinding
/
Cutting
Safety
LOTO
Fire
Prevention
&
Protection
Defensive
Driving
Course
First
Aid
Training
Safety
Observation
Card
Training
Tool-Box-Talk
Training
Electrical
Safety
PPE
Ladder
Safety
Lifeline
Safety
Compressed
Gas
Cylinder
Safety
Environmental
Management
Dust
Control
Noise
Road
&
Traffic
Safety
Hazard
Identification
Fatigue
Safety
Chemical
Handling
Vibration
Safety
Other
Courses
Driving
Course
Equipment
Operator
Certification
OTHER
COURSES
x x x x x
x x x x x
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x x x x x x x x x
Skilled Carpenter, Electrician etc x x x x x x x x x x x x x
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x x x x x x x x x x x x
x x x x x x x x x x x x x x x x x x
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x x x x x x x x x x x x x x x x x x
0 x x x x x x x x x x x x
SPECIALIZED
COURSES
Position / Trade
Plant operators and Drivers
Third Party
Rigger
Security personnel
HSE SPECIALIZED TRAINING
HSE
Induction
Construction Manager
Site Engineer
Foremen
Land Surveyor
Labour
Banksmen
Flagmen
HSSE Officer
HSSE TRAINING MATRIX
The training matrix is meant to help organize and track training needed for employees and workers
Page 33 of 87

Toolbox talks for
construction workers
Typically toolbox talks last 10 to 15 minutes, may
take place once a week, involving small groups of
up to 10 people. Given by a foreman.
• Slips, trips and falls.
• Work at height, use of ladders and scaffolding.
• Work near existing services.
• Roofing.
• Manual handling.
• Welding.
• Electrical hazards.
• Working in confined spaces.
• Falling objects.
• Fire safety.
• Night working.
• Traffic safety.
• Construction plant, equipment and tools.
• Excavation.
• Hazardous materials.
• Eye protection, head protection, hearing
protection and so on.
Page 34 of 87

SAFETY RISK ASSESSMENTS for Airside Construction Doc Ref -
Project - ABC Works By - David H Moloney Date – 01/01/01
Page 1 of 7 of Risk Assessment
Nr. HAZARD EFFECT
RISK ANALYSIS /
NO CONTROLS CONTROL MEASURES
RISK ANALYSIS /
WITH CONTROLS
Residual
Risk
remarks
Severity likelihood risk severity likelihood risk
General Airside Working
1 Lack of Airside
safety awareness
• Cause damage &
Injury
• Impact negatively on
airport operations
6 6 36 • Staff to receive airside safety training.
• Risk Assessments & Method of Work Plan to
be briefed to all affected workers.
• Airside induction
• Pre start-up and regular site meetings
should be held to ensure safety
requirements are met.
• Promotion of safety awareness through
training.
• Staff should be familiar with Annex 14 for
design and operation of airports.
6 2 12 Adequately
Controlled
Risk
2 Construction that
impacts on the safe
operation of airport
• Cause damage and
injury
6 6 36 • Method of Work Plans to be submitted and
approved by stakeholders prior to any work
starting
• Notams to be issued where necessary.
• A close working relationship between the
contractor, airport operator and
stakeholders will enhance safety at the
airport
• Ensure clean and tidy storage and proper
disposal of materials and waste
6 2 12 Adequately
Controlled
Risk
Page 35 of 87

Nr. HAZARD EFFECT
RISK ANALYSIS /
RISK ANALYSIS /
WITH CONTROLS
Residual
Risk
remarks
3 Unauthored
Persons in security
restricted area.
• Terrorist Attack
• Not aware of Safety
8 4 32 • All those entering airside to have a pass and
to be checked by security.
• Security Screening to check for concealed
prohibited items.
• Prior Safety training.
8 2 16 Adequately
Controlled
Risk
4 Collision with
aircraft in flight
• Severe damage
• Fatalities
• Public outcry
10 4 40 • Fan corridor height restrictions briefed to all
site teams
• Works in the fan corridor will be controlled by
Restricted Area Access Work Permits
• Height markers ( such as goal posts ) shall be
constructed as applicable to advise of height
limits
• All plant equipment shall be selected on basis
of maximum operating heights so as to not
interfere with airport operations
• Supervision at all times.
• Any plant operating at heights must not
infringe the protected surfaces, inside or
outside the airport property limits
• Crane operating heights should be checked
to ensure no protected surfaces are
infringed.
10 2 20 Adequately
Controlled
Risk
5 Lighting for night
working
• Distracts, dazzle and
blind pilots and ATC
8 4 32 • Lights shall be shielded so direct light does not
shine above the horizon.
8 2 16 Adequately
Controlled
Risk
6 FOD- Foreign • Damage to aircraft
tyres, engines
4 6 24 • Continuously remove waste or loose 4 2 8 Negligible
Page 36 of 87

Nr. HAZARD EFFECT
RISK ANALYSIS /
RISK ANALYSIS /
WITH CONTROLS
Residual
Risk
remarks
Object Debris • Injury materials
• Vehicles entering or exiting the worksite
may need to be cleaned to prevent mud or
debris being deposited in the airside area
• Ensuring the workforce are committed to
active FOD prevention
• Maintaining good housekeeping practice
•Suitable site fencing should be installed to
protect from jet blast and to ensure FOD is
contained within the site
•Staff should remove and dispose of any
FOD found
Risk
7 Bird Strikes • Damage to aircrafts
• injury
4 4 16 • Don’t attract birds by feeding them.
• Dispose of waste food properly using bins
4 2 8 Negligible
Risk
8 Equipment or
material near
NAVAIDs
Navigational Aids
• Degrade or impair
radiated signals
• Injury
4 4 16 • Keep area in front of localiser and glide slope
free.
• Know the ILS sensitive areas
• Providing warning signs, markings or
lights at the edge of the sensitive area to
prevent accidental intrusion into the
sensitive areas
4 2 8 Negligible
Risk
9 Failure to control
dust.
•Obscures or
diminishes the
visibility of areas
•Injury
6 4 24 • Use dust suppression by wetting surface.
• Use sheeting on trucks transporting fine
materials
• Sweep up dust
6 2 12 Adequately
Controlled
Risk
10 Inappropriate or •inadequate to 4 4 16 • Ensure fencing is adequate 4 2 12 Adequately
Page 37 of 87

Nr. HAZARD EFFECT
RISK ANALYSIS /
RISK ANALYSIS /
WITH CONTROLS
Residual
Risk
remarks
poorly maintained
fencing
separate
construction areas
•Injury
• Maintain fencing Controlled
Risk
11 Jet Blast •Injury 6 6 36 • Protect construction workers from jet blast
• Ground crews are to ensure areas behind
the aircraft are clear, and that the aircraft is
positioned in such a way as to avoid
concentrating break-away blast at
buildings, parked or taxiing aircraft or
persons on the apron
6 2 12 Adequately
Controlled
Risk
12 Driving Airside • Accidents
• Injury
6 6 36 • All contractor drivers must be escorted by
a qualified vehicle operator or undergo
airside driver training and testing Access
routes should be agreed to and clearly
identified to minimize interference with the
operation on the airport
6 2 12 Negligible
Risk
13 Fire • Damage
• Injury
6 6 36 • Smoking restrictions should be described,
monitored and enforced
• Hot works restrictions (possibly involving
a separate hot works permit) should be
described, monitored and enforced
• Mobile phones should be switched off
when refueling plant so as not to ignite
fumes.
• No smoking.
• Fire extinguishers to be provided
6 2 12 Negligible
Risk
Page 38 of 87

Nr. HAZARD EFFECT
RISK ANALYSIS /
RISK ANALYSIS /
WITH CONTROLS
Residual
Risk
remarks
14 Spillage of fuel,
oil, substances
• Injury by trips and
falls
6 6 36 •Provide spill kits
•Deal with spills straight away
•Spills should be thoroughly cleaned and
dried.
6 2 12 Negligible
Risk
15 Jet Noise • Hearing lost 4 6 24 • Wear ear protection 4 2 8 Negligible
Risk
16 Jet Fumes • Itching of the eyes
• Sore throat or
coughing
6 6 36 •Wear eye protection
•Wear face mask / respirator
6 2 12 Negligible
Risk
17 Implement
Change e.g.
temporarily closing
runway
• Accidents leading
to damage & injury
6 6 36 •Communicate proposed changes with
stakeholders.
•Issue Notam
6 2 12 Negligible
Risk
18 Emergencies • Damage & Injury •Call the Emergencies Services
•Issue Pocket Card entitled Airport
Emergency Contacts with phone numbers
for Firefighting & Rescue. Medical,
Control Tower, Security, Airport
Manager.
•Be familiar with the airport emergency
Page 39 of 87

Nr. HAZARD EFFECT
RISK ANALYSIS /
RISK ANALYSIS /
WITH CONTROLS
Residual
Risk
remarks
plan
Note - The Control Measures are used to reduce the Likelihood and thereby the Residual Risk
A Hazard is the potential to cause harm. A Risk is the likelihood of harm taking place.
Table
Value Severity Value Likelihood Residual Risk - Ratings & Actions
10 Multiple Fatalities 10 Certain
Risk valve is obtained by multiplying the hazard’s
severity value by the likelihood value. The severity
value remained the same, without or with controls,
it is the likelihood valve that the controls will
reduce
8 Single Fatality or Permanent Disability 8 Very Likely 60 - 100 Intolerable Risk
6 Major Injury loss of time >3 days 6 Likely 32 - 48 Moderately Controlled Risk
4 Minor or Serious Injury 4 May Happen 12 - 24 Adequately Controlled Risk
2 Slight injury 2 Unlikely 0 - 8 Negligible Risk
Aim of Risk Assessment - To find solutions that would eliminate, mitigate, or manage the risks to an acceptable level.
Risk Assessment Matrix ( Risk = Severity x Likelihood )
Severity of Hazard Likelihood of Hazard
Certain
L-Value =10
Very Likely
L-Value = 8
Likely
L-Value = 6
May Happen
L-Value = 4
Unlikely
L-Value = 2
Multiple Fatalities S-Value = 10 100 80 60 40 20
Single Fatality or Permanent
Disability
S-Value = 8 80 64 48 32 16
Major Injury loss of time >3 days S-Value = 6 60 48 36 24 12
Minor or Serious Injury S-Value = 4 40 32 24 16 8
Slight injury S-Value = 2 20 16 12 8 4
Page 40 of 87

The numbers in the coloured cells are the Risk Values, obtained by multiplying the Hazard’s Severity by the Likelihood values.
Green
Amber
Red
No further action required
The current residual risk requires a review of available options and action
The current residual risk requires further action to reduce it.
Images
Page 41 of 87

Risk Assessment
Understanding HAZARD versus RISK
HAZARD
Is the potential to cause harm
RISK Value
Is the combination of the Hazard’s
Severity Value & Likelihood Value
Crossing a street,
vehicles are a
Hazard
The RISK of an accident is
HIGH when crossing a street
The RISK of an accident is
LOW when crossing a street
at a Pedestrian Crossing
Page 42 of 87

COSHH ASSESSMENTS
MUSCAT INT’L AIRPORT – MC1 CONTRACT
Page 1 of 2
Introduction: Many hazardous substances are used in the construction industry COSHH Assessments must be carried out with the aim of elimination,
substitution and reduction of exposure to hazardous substances.
Hazardous Substance :- Bitumen
Description :- Bitumen product for road building.
Use :- Paving material
Storage Precautions :- Store away from moisture and sources of ignition
Disposal Procedure :- Dispose of via an authorised person / licence waste disposal contractor.
Spillage Procedure :- Contain and recover liquid using sand or other inert absorbent.
Health Effects Controls First aid measures & Emergencies
Eye contact -
Hot product may cause severe eye burns and/or blindness.
For normal operations with hot material wear safety hat with
visor.
• Hot product - If contact with hot product, cool
the burn area by flushing with large amounts of
water for twenty minutes.
• Do not attempt to remove anything from the
burn area or apply burn creams or ointments.
• Cover the burn area loosely with a sterile
dressing, if available. Transport to the nearest
medical facility
• for additional treatment.
• All burns should receive medical attention.
• Cold product - Flush eye with copious quantities
of water. If persistent irritation occurs, obtain
medical attention.
Skin burns –
Contact with hot material can cause thermal
burns which may result in permanent skin damage.
For normal operations with hot material wear heat resistant
coveralls, (with cuffs over gloves and legs over boots), and
heavy-duty boots, e.g. leather for heat resistance. The use of
a neck apron is recommended.
• If contact with hot product, cool the burn area by
flushing with large amounts of water.
• Do not attempt to remove anything from the
burn area or apply burn creams or ointments.
Cover
• the burn area loosely with a sterile dressing, if
available.
• Transport to the nearest medical facility for
additional
• treatment. It should be noted this product
Page 43 of 87

COSHH ASSESSMENTS
MUSCAT INT’L AIRPORT – MC1 CONTRACT
Page 2 of 2
contracts on cooling.
• Where a limb is encased, care should be taken
to avoid the
• development of a tourniquet effect. In the event
of this
• occurring the adhering product must be
softened and/or split to
• prevent restriction of blood flow. All burns
should receive medical attention.
Ingestion –
Under normal conditions of use, this is not expected to
be a primary route of exposure.
Wash hand thoroughly before eating, drinking, smoking,
and use rest room after contact.
• If contamination of mouth occurs, wash out
thoroughly with water. Do not induce
vomiting, obtain medical advise.
Inhalation –
Inhalation of vapours or mists may cause irritation to the
respiratory system.
No respiratory protection is ordinarily required under
normal conditions of use. Use self contained breathing
apparatus in places where hydrogen sulphide vapours
may accumulate.
• If inhalation of mists, fumes or vapour
causes irritation to the nose or throat,
remove to fresh air.
• If rapid recovery does not occur, obtain
medical attention.
• Casualties suffering ill effects as a result of
exposure
• to hydrogen sulphide should be removed to
fresh air.
• Do not attempt to rescue the victim unless
proper respiratory protection is worn.
• If the victim has difficulty breathing or
tightness of the chest, is dizzy, vomiting, or
unresponsive, give 100% oxygen with
rescue breathing or Cardiopulmonary
Resuscitation (CPR) as required and
transport to the
• nearest medical facility.
Page 44 of 87

Muscat Airport Expansion Site Articles By David H Moloney
Page 1 of 34 of PEP Articles
Muscat Airport Runway Construction
Project Execution Plan Articles
By Mr. David H Moloney Author
Page 45 of 87

Contents
1. Scope, Resources, Facilities & Logistics
2. SUPERPAVE PmB Asphalt Runway Pavement
3. Airfield Pavement Concrete by Slipform Paver
4. Operation of Site Precast Yard
5. Onsite Material Testing Laboratories Operation
6. Crushed Aggregate Base Course (CABC) - Place, Compact & Test
7. Earthworks Activities
8. Onsite Concrete Batching Yard Operation
Page 46 of 87

Intentionally Blank
Page 47 of 87

Muscat International Airport Expansion - Phase 1 - Civil Works
Package (MC1) by David H Moloney
Expansion of Muscat Airport, Main Civil Contract.
Scope, Resources, Facilities & Logistics.
Map showing Existing and Expanded Airport
Introduction
Consolidated Contractor Company and TAV Construction in a joint venture are
constructing the main civil contract for the expansion of Muscat Airport. The
contract value is 1.2 billion dollars.
CCC Oman is a subsidiary of Consolidated Contractors Group SAL (CCG), a
Lebanese multinational company headquartered in Greece. CCG and its
subsidiaries around the region boast a combined workforce of 120,000
employees and revenue of $5.5bn its origins go back to 1952. CCC workforce is
composed of more than 80 nationalities, in almost every country of the Middle
East, Africa, Europe. CCC is the largest engineering and construction company
in the Middle East. CCC has operated in OMAN for many decades.
TAV Construction is a member of the global airport brand TAV Group, TAV
Construction was established in 2003 with the vision to become a leading brand
in airport construction. In less than a decade, the Company achieved to
undertake and realize projects worth US $ 15 billion in contract value.
Engineering News Record (ENR), one of the most reputable publications in the
construction industry, ranks TAV as the World’s 4th largest airport contractor.
Scope of Main Civil Contract
The project consists of the following:-
• A new 4.3 km long runway, new aprons and taxiways, renovation of the
current runway and taxiways.
• Airport access highway with 3 lanes per carriageway, 2# interchanges &
7# bridges.
• Electricity substations and underground electricity power lines.
• Fuel farm, fuel pipelines and hydrant pit systems.
• Chiller buildings with cooling towers and chilled water storage tanks.
Generator buildings.
• Storm water culverts, channels and pipelines. Potable, fire fighting,
irrigation and chilled water pipelines,
• Potable and fire fighting water storage tanks and pumphouses.
• Ground improvement by surcharging & stone columns. Insitu concrete
piling. Landscaping.
Design of Airport
Existing Airport
The existing passenger terminal building handled 4 million passengers in 2011,
the runway is 3,400m long by 45m wide. There are parking stands for 34
aircrafts. Buses are used to transport the passengers from the bus lounges to the
aircrafts. The aircraft stands type are “self-manoeuvring” where the aircrafts taxi
in and out under their own power.
Airport Expansion
The New Passenger Terminal will have an initial capacity of 12 million
passengers annually with the provision to expand to 48 million passengers per
annum. The terminal is positioned between the existing and new runway, for
easy aircraft movements and to minimise taxiing time from the runways to the
parking stands. Also to increase the turnaround time between flights. To increase
the transfer time of passengers from aircrafts to the piers there are 29 #.
passenger boarding bridges to contact aircraft stands. Also there are 10# bus
boarding lounges and 30# remote aircraft stands. The total floor area of the
terminal is 340,000 square metres. There is a multi storey car parks with 8,000
spaces. The new Cargo Terminal with an annual capacity of 260,000 tonnes.
New Access Highway
Existing Airport
Page 48 of 87

A new access highway with 3 lane per carriageways will connect the new
terminal to the main roads outside the airport with two major interchanges. In
total there is over 53 km of multi lane carriageways.
List of Main Project Quantities
• Earthworks – Excavation 17 million cu m, Imported Rock Fill 18 million cu
m, RipRap 370,000 cu m
• Concrete - 840,000 cu m, including 183,000 cu m of pavement concrete.
• Pavements – Asphalt 1,550,000 tonnes, Crushed Aggregate Base course
1,1 56,000 cu m, Granular Subbase 691,000 cu m.
• Bridges 7#,
• Carriageways multi lane 53 km,
• Interchanges 2#.
• Airfield Lighting - Duct trenches 300 km, Ground Lights 10,000#,
Chambers 600 #, Sign boards 260#, AGL cables 760 km.
• Electricity - 132kV cables 93 km, 11kv cables 213km, Substations
39# Transformers 132kv to 11kv 7#, 11kv to 0.433kv 104#
• Stone Columns 142,000# 769,000 lin m,
• Piles Insitu 1,225 # 14,000 lin m
• Pipelines – Sewer 20km with 326# chambers, Chilled water 24 km with
76# chambers, Potable water 29km with 219# chambers, Fire fighting
30km with 298# chambers.
• Fuel Farm & Hydrant System – Pipelines 500mm dia. 15km, hydrant pits
150# & valve chambers 17#.
• I.T. Network AWAN – Underground cables 83km.
• Fibre Optic - underground cables 33km
• Low Voltage & Street Lighting – 550 km
Photo of Project Camp
Resources Employed
Project Camp
• A Project Camp to accommodate 8,000 + workers and staff was
constructed 9 miles inland from the site. The camp consists of:-
accommodation blocks, messes, clinic open 24hours, Masjid, laundry,
kitchens, money exchange, groceries & clothes shops, gymnasiums,
sports facilities for volley-ball, basket-ball, cricket & football. Workshops,
food stores for frozen, dry and fresh foodstuffs, sewerage treatment plant,
fresh water storage tanks, generators.
• On a recent Wednesday over 11 tonnes of food are consumed, the list of
foodstuffs was:- Meat 250 kgs, Chicken 2.6 tonnes, Vegetables 2.6
tonnes, Fruit 1.2 tonnes, Rice 2.15 tonnes, Dry items 2 tonnes, Sugar 250
kgs, Salt 75 kgs, soft drinks and orange juice 8000 # cans..
Staff
• At peak 800 # staff includes office and site staff down to chargehand
level.
Labour - Joint Venture’s Employees
• At peak there were 8,000 # employees. 74 # buses are used to transport
the works from the camp to the site.
Page 49 of 87

Subcontractors
Specialist subcontractors were employed for the MEP installation, post
tensioning of bridges, fuel hydrant system, structural steel, roof covering, riprap
and building finishing trades. At peak subcontractors had 3,200 # employees.
Local Suppliers and Subcontractors.
Where possible the materials, machinery and equipment to be incorporated in
the permanent works were purchased within the Sultanate of Oman either
directly or through subcontractors. 91% of the materials were obtained locally.
Also local subcontractor were employed to carry out specialist and finishing work
activities
Health, Safety, Security & Environmental
The main objective is to ensure that the site is a safe place to works and the site
is environmentally friendly. Recently the joint venture achieved 40 million man
hours without a long term injury which is a remarkable achievement and proof of
the safety culture on site.
Safety Success & Measures
To date over 66 million man hours have been worked on site by a total of 57,000
individuals at different stages of the project from 15 nationalities. The peak
number of workers on site at any one time was 12,000.
The main safety indicators achieved are:-
• Fatalities = zero.
• Highest number of hours worked without a Lost Time Injury or incident
(LTI) = 41 million.
• Total recordable LTI's = 6 numbers
Safety training is given covering 51 different subjects in 5 languages in the site
Training Centre to ensure that individuals are trained at and in the use of
equipment they will use and made aware of the hazards and controls to minimise
or eliminate the risks associated with work that they will supervise or perform.
Before anyone under the control of the CCC starts on site they have to attend a
site safety Induction to become familiar with the risks and safety procedure on
site. A site specific Safety Video that was filmed on site and is used to visually
communicate and familiarise team member with the site which is 10 km long by 4
km wide at its maximums.
Programme & Stages of Construction
There are two main stages, firstly to constructing the new runway and connecting
taxiways to the existing Airport apron to enable aircraft to use the new runway
and taxi from the existing airport. The second stage is to upgrade the existing
runway and taxiways.
Quality Assurance and Control
There is a set of site procedures designed to ensure that quality standards and
processes are adhered to, that the final product meets or exceeds the required
technical and performance requirements. There are two number site laboratories,
one for testing concrete, soils and aggregates and the second for testing
pavement asphalt, polymer modified bitumen, prime and tack coat.
Technologies Used
Asphalt Pavement.
Page 50 of 87

Photo of Asphalt Laydown & Compaction – 4# Pavers in Echelon
The runway and taxiway surface comprises three layers of Superpave Polymer
modified Bitumen (PmB) Asphalt. The asphalt pavement is a Superpave System
that includes a performance-based asphalt binder specification, a mix design
analysis system, specific new test procedures, and specialized testing
equipment. Materials are tested on site, within a fully equipped Superpave
asphalt testing laboratory for compliance with the specification. The site
laboratory is the only fully equipped laboratory of this type in the Middle East.
Airfield Pavement Concrete by Slipform Pavers
Photo of Concrete Slipform Plant
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. Vibrators fixed along
the front of the paver consolidate and fluidize the concrete. The concrete is then shaped
by passing between the vertical side forms and underside of the horizontal profile pan as
the paver moves forward. Finally the top surface is brushed to provide a texture and
curing agent is sprayed to the top and side surfaces.
Obstructions & Problems.
The design was not completed prior to start of construction. Large sections of the
works were put on hold awaiting drawings. There are many variations and
changes to the design. Other major projects on site were late starting this lead to
many unknowns at to interface issues.
Working Hours
Working hours are generally Saturday to Wednesday inclusive 7am to 5:30pm
and Thursday 7am to 1pm. During hot weather concreting is carried out at night
and all the airfield pavement concrete is placed at night. In summer no work is
carried out between midday and 3pm because of the high temperatures. During
the holy month of Ramadan reduced hours are worked.
Photo of Aprons, Taxiways & Runway
On Site Manufacturing & Facilities
• Concrete Batching Yard - There are 3 nr. batching plants with a combined
capacity 250m3 per hour. Also there is a batching plant for producing
Crushed Aggregate Basecourse.
• Asphalt Batching Yard. - There are two batching plants manufactured by
Marini & Wibau with a combined capacity 450 tonnes per hour
• Reinforcement Cutting & Bending Yard processed 50,000 tonnes of
reinforcement.
Page 51 of 87

• Precast Concrete Yard. Total volume of concrete used was 1,400 cu m.
• Site Laboratories – tested asphalt, concrete, granular fill and soils for
compliance with the specification.
• Stores & storage yards for materials and equipment.
• Offices for the joint venture and the Engineers staff.
• Site Clinic 2# open 24 hours, with ambulances.
• Firefighting Equipment
• Plant & Equipment Yard for fuelling, servicing, storage, maintenance and
repairs.
• Dewatering pimps, hoses, settlement lagoons and sea outfalls.
• HSE Training facilities.
Satellite Image January 2013
Quarry & Aggregate Production
Quarry and aggregate production facility in located 12 miles from site in the
foothills of the Al Hajar Mountains. The crushing & screening plant has a capacity
of 320 tonnes per hour and operates 24 hours per day for 6 days per week. At
the peak there were 4 blasts per week. Aggregates are produced for concrete,
asphalt pavements, crushed aggregate basecourse, fill and sub base course and
backfill.
Main Plant & Equipment
At peak – Dozers 25#, Graders 19#, Excavators 24#, Tipper trucks 143#, Trucks
with tipping trailers 62#, Cranes 23#, Compaction rollers 38#, Pavers 6#,
Concrete trucks 9#, Concrete mixers 4#. Dewatering pumps 9#, Buses 66#.
Other plant items are generators, compressors, water tankers etc.
Site Entrances & Roads
There are four entrances manned by security and the main site roads are dual
carriageway. The speed limit is set at 40 km per hour and is monitored by hand
held speed camera. The site roads have speed ramps. At two of the entrances
there are weigh bridges with sheeting towers and wheel washer. The gates are
manned by security personnel.
Site Roads Network
Page 52 of 87

Construction Practices and Techniques
See the following separate articles that deal with the construction practices and
techniques used:-
• Construction of Bridge 185
• Highway on Embankment
• Asphalt - Airfield Pavement
• Concrete - Airfield Pavement
• Precast Yard Operation
• Site Laboratories Operation
• Reinforcement Yard
• Crushed Aggregate Base-course
• Earthworks
• Concrete Batching Yard
Also see technical videos that are a record of how the work is carried out on site
and are an informative, good training and educational tool.
• Site Logistics
• Camp Accommodation
• Concrete Batching Yard & Laboratory – Operation
• Reinforcement Yard - Operation
• Precast Yard - Operation
• Dewatering Site
• Earthworks
• Crushed Aggregate Base-course - Lay, Compact & Test
• Asphalt Pavements
• Concrete Pavements
• Roads & Bridges Construction
• Post Tensioning Bridge – How it is done
• RipRap Slope Protection - Construction
• 11kv cable laying
• Airfield ground Lighting - Construction
• Underground Utilities
• Chiller Buildings Construction
• Terminal Building & ATC Tower
• Work Method Charts
• Airport Fence
• Piling & Stone Columns
• Roof Coverings.
Page 53 of 87

SUPERPAVE PmB Asphalt Runway Pavement
By David H Moloney For CCC/TAV JV
Introduction
CCC in a Joint Venture Project with TAV are undertaking the civil contract
on the Development of Muscat International Airport (DMIA). Works include the
construction of a new 4,000 metres long by 60 metres wide runway and
associated taxiways as well as refurbishment of the existing runway. The
runway surface comprises three layers of Superpave Polymer modified Bitumen
(PmB) Asphalt on 370mm thickness of crushed aggregate base course, on 2 to
6 metres thickness of rockfill.
Superpave
The asphalt pavement is a Superpave System that includes a performance-
based asphalt binder specification, a mix design analysis system, specific new
test procedures, and specialized testing equipment.
Rock Extraction
Rock for the asphalt aggregates is blasted, crushed and screened fourteen
miles from site at the joint venture’s quarry and aggregate processing yard in
the Al Hajar Mountains. The rock is Gabbro which is an intrusive igneous rock
that is grey in color, moderately strong to strong in strength and has a
composition similar to basalt. The contract required that a detailed Aggregates
Resources report was produced and submitted for acceptance by the engineer.
This was completed and quarrying works
subsequently commenced. Extraction of the Gabbro rock is undertaken by
drilling and blasting a face on the mountain side. The open face practice of
drilling and blasting rock benches, secondary breaking of any over sized rock,
loading of blasted rock by excavators and hauling to the primary crusher using
30 tonne capacity lorries is utilised. Drilling is done with heavy duty down the
hole / top hammer drill rigs to a preset pattern of holes at 2.5 to 3m centres
longitudinally and 3m centres from face. The holes are charged with explosives
and the top 2.7 m is stemmed with grit to minimise fly rock. The explosives in
the holes are detonated in a set firing pattern to fragment the rock. Any
fragmented rock that is contaminated with clay or fine weathered rock or shale
is passed over a grizzly static screed to separate the good rock from the
deleterious material. The average blast size is 100m long by 9m wide by 20m
deep and produces 18,000m3. Blasting is carried 4 days every week.
Aggregate Production
Rock crushing is undertaken with high-tech equipment: primary and
secondary crushers manufactured by Metso. A Barmac crusher is used to
cubically shape the aggregate. The crushed rock is screened into the required
aggregate sizes for mixing on site to produce the pavement asphalt. The
aggregates are dispatched by trucks to site. Trucks are weighted at the
weighbridge, given a load out ticket specifying material requirement and
directed to the correct stockpile. Loaded trucks are passed back through the
weighbridge to be weighted again to calculate their load weight.
Aggregate Storage at the Asphalt Yard
The aggregates are stored in stockpile bays where the different sizes of
coarse and fine aggregates are kept separated by walls. Front end loaders are
used to fill the cold bins of the asphalt plant.
Polymer modified Bitumen
Page 54 of 87

Bitumen grade 60/70 from BABCO refinery (Bahrain Petroleum Company)
is supplied by Shell and delivered to site by road from Jebel Ali Port in Dubai.
On-site the bitumen is mixed with polymer in the Massenza Blending Plant to
produce the PmB. The PmB provides prolonged life and enhanced pavement
performance. The PmB blend is that of 60/70 straight run bitumen, and
butadiene-styrene copolymer, Commercial name of PmB is Cariphalte PG 76-
22
Tack & Prime coat
The bituminous MC-70 prime coat and CSS-1h tack coat will be produced on
site. The MC-70 prime coat is applied with a lorry mounted sprayer at a rate of
0.50 kgs per m2 at a temperature of 90*C.
Asphalt Production
Hot bitumen PmB is mixed with the heated aggregates in the two on-site
asphalt batching plants that are manufactured by Wibau and Marini with a
combined output of 480 tonnes of asphalt per hour. The type of asphalt plants
are “Batch Asphalt Plants” and the major components are the aggregate cold
bins and feed system, aggregate dryer, mixing tower, emission control system,
bitumen storage tanks and supply system and the asphalt storage bins and truck
loading system. The temperature of the asphalt is in the 160 to 180*C range
when produced. ,
Site Trials .
Prior to starting paving all the materials were pretested and a site trial was
carried out to familiarise the crew with the equipment and the characteristics of
the particular PmB asphalt mix and to ensure that the workmanship, as well as
the material, complies with the specification requirements.
Laying
The PmB Asphalt is laid with two tracked Vogele Pavers Super 1900-2
equipped with extending screed, tamper and vibrators, auger and conveyor,
working in echelon in a staggered formation producing a fifteen metre wide mat.
Level control is maintained by two string-lines as a grade reference system for
the lead paver and a matching shoe and one string-line for the following paver.
The pavers operate using an automatic screed control, which controls the screed
height using the string-line or the matching shoe as a level reference. The un-
compacted asphalt level behind the paver is checked by pulling a string-line
between the longitudinal string-lines at the ten metre chainage pin locations and
taking dip measurements using a tape measure. The asphalt with compaction
reduces in thickness by approximately 20%.The jointing and laying sequence
across the runway is designed to ensure that the longitudinal joints are staggered
by 300 mm between layers, free edges that will form joints are cut back by
100mm.The level tolerance is +/- 6mm and the smoothness tolerance is a
maximum of 6mm with a 3m long straight edge. Average output is 4 to 5 loads
per hour = 120 tonnes per hour
Compaction
The asphalt is compacted using a combination of tandem drum steel rollers
and pneumatic tire rollers (PTR) to compact the asphalt to the required density
and provide a good surface, texture and rideability. The rolling pattern that is
used was determined during a site trial where three roller test strips were laid
and the asphalt densities obtained by cores were correlated with different rolling
patterns. The rolling pattern used is: Initial or Breakdown Rolling by steel drum
tandem rollers 3 passes static and 1 pass with vibratory. Intermediate Rolling 6
passes with pneumatic tyre rollers (PTR). Finish Rolling using steel drum
tandem rollers 1 pass vibratory and 3 pass static. The compaction requirement
is 94% of maximum theoretical density.
Material Testing
Materials are tested on site, within a fully equipped Superpave asphalt
testing laboratory for compliance with the specification. The site laboratory is the
only fully equipped laboratory of this type in the Middle East. The following are
some of the tests that are carried out;- Finish levels are tested by Engineer’s
Level, smoothness by using straight edge, compaction / densities by sample
cores, ingredients by samples sent to the laboratory, temperature by digital
thermometer, thickness by cores and tensile strength by cores.
Crew & Outputs
Generally working a 9 hour day. Average output per 9 hour shift for each paver
crew is 750 tonnes. The equipment comprises 1# tracked paver, 2# PTR rollers,
2# tandem steel drum rollers, 1# Tanker truck part time 8# tipper trucks. The
Page 55 of 87

paver crew comprises 5 drivers, 2 screw men, 4# Rakers, 2 labourers, & a
survey crew of 5# persons.
Conclusion
The Runway is the first of its kind in the Middle East. It has an a pavement
thickness made up of 70mm base course, 50mm binder course, and 40mm
wearing course, total 160mm thickness which was designed by the engineers
to take the weight of the A380 Airbus at 592 tonnes.
There is not another Runway within 6,000 miles that even resembles this state
of the art structure.
Millions of tons of rock were transported from the JV quarries to create the
foundation for this runway, Crushed rock was placed in 500 mm thick layers.
The runway is elevated above the existing ground level
From first impressions one may conclude that this runway was a build operation
like any other. The team from DMIA undertook the challenge of getting the
Engineers approval for aggregates, bitumen, PmB, paving equipment, method
statements for production and laying, factual reports on site trials, attending
numerous meetings with the Engineer, responding to the Engineers queries,
and countless discussions all of which was a mammoth task.
Due to the successful collaboration of the Joint Venture Team and the
dedication of its employees, we now have the newest runway in the Middle
East, a first of its kind. Surrounding GCC countries will no doubt look to this
project when building similar runways in the future. And now for a smooth take
off!!
Page 56 of 87

Project Execution Plan for Muscat Runway Construction, Oman

Project Execution Plan for Muscat Runway Construction, Oman

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