Runway Construction Project Execution Plan

Runway Construction Project Execution Plan
Details of how a Runway is constructed, and how the progress, safety and quality will be monitored and controlled.
Also the measures to ensure that the site is environmentally friendly.
David H Moloney
14th Oct 2016
Brief Description
The purpose of this presentation is to give an understanding of the Methods, Plant
and Sequence to construct a Runway .
This presentation can be used to engage Stakeholders and to get the Site Teams
commitment to the programme. Also can be used for Induction Training and as a
way to capture and share knowledge.
Project Execution Plan (PEP) details how a project will be executed, monitored and
controlled.
High in Educational Value and easily understood. Recommended for Continuing
Professional Development (CPD)
This Video Presentation is innovative and has many beneficial uses.
http://www.slideshare.net/DavidHMoloney/runway-construction-project-execution-plan
Film at https://youtu.be/yCKLPzrDztw
© David H Moloney

Table of Contents
© David H Moloney

Runway Construction
© David H Moloney

Runway Construction Sequence & Methods
Roads&Pavings
© David H Moloney

Excavate & Load Tipper Trucks
© David H Moloney

Trench Excavation with Stepped Faces
© David H Moloney

Trench Excavation with Battered Faces
© David H Moloney

Spreading & Compaction Clay fillEarthworks

Dozer Ripping GroundEarthworks

Excavator with Hydraulic RockbreakerEarthworks

Rock - Excavability
The excavability of rock depends mainly on the rock strength and the layer thickness.
This diagram shows excavation methods for rock of various strengths and thicknesses,
with a free face.
ⓒ David H Moloney

CABC ( Crushed aggregate base course )
Earthworks
Mixing Plant
Testing Compaction
Site Trial

Spreading & Compaction CABC ( Crushed aggregate base course )
Earthworks

Spreading & Compaction CABC ( Crushed aggregate base course )Earthworks

Runway Asphalt Pavement
Roads&Pavings
Brief Description
Sequence, plant and methods to construct a runway

Prime Coat Site Trials
Roads&Pavings
Bituminous Prime Coat shall
consist of supplying and applying
bituminous material to a previously
prepared and approved base
course in accordance with the
Specification to ensure a bond
between this surface and the
overlying course.

Runway Asphalt Pavement - Prime Coat
Roads&Pavings

Runway Asphalt Pavement
Roads&Pavings

Runway Asphalt Pavement - 4 Pavers working together
Roads&Pavings

Runway Asphalt Pavement - Line & Level
Roads&Pavings
Checking asphalt level by Dip measurements
String line used for Level & line reference

Runway Pavement - Marking
Roads&Pavings

Runway Pavement – Cleaning surface with rotating water jets
Roads&Pavings

Runway Pavement – Test for Skid Resistance
Roads&Pavings

Runway Pavement
Roads&Pavings
Using the Douglas Mu-Meter continuous friction measuring equipment

Runway Pavement – Test for Smoothness using Rolling Straight Edge
Roads&Pavings

Runway Pavement – Test for Texture by Sand Patch test
Roads&Pavings

Airfield Ground Lights Ducts & Chambers
Miscellaneous

Airfield Ground Lights
Miscellaneous

Airfield Ground Lights Excavate Trench in CABC
Miscellaneous

Airfield Ground Lights – Concrete Ducts
Miscellaneous

Airfield Ground Lights – Surface Inset Lights
Miscellaneous

Miscellaneous
Jig to Level Pot

Airfield Ground Lights - Core drill for Inset Light
Miscellaneous

Airfield Ground Lights Fit Pot with Jig
Miscellaneous

Precast Yard - Chambers
Miscellaneous

Delivery of Precast Chambers
Miscellaneous

Miscellaneous
Jointing HDPE Ducts Jointing HDPE Ducts
Precast Chamber Grouting Inset Light Pot

ILS Localiser Antenna & Approach Lights
Miscellaneous
Provides lateral radio guidance to an aircraft
approaching and landing on a runway

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

ILS Glide Path Antenna
Miscellaneous Provides radio vertical guidance to an aircraft approaching and
landing on a runway

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

Airfield Lights - Substation
Miscellaneous
Contains switchgear, protection and control equipment

Airfield Lights – Taxi Guidance Signs
Miscellaneous
Taxi guidance signs provide direction and
information to taxiing aircraft.

Concrete Slipform Paving
Roads&Pavings
Brief Description
Horizontal slip forming for concrete pavement. The process
consists of placing and spreading low slump concrete on the
ground in front of a paver that slips over the concrete and
extrudes strips of slabs.
Slipform Concrete Paver
Spreader
Texturing
& Curing

Concrete Slipform Paving – Texturing Machine
Roads&Pavings

Concrete Slipform Paving - Slipform Machine
Roads&Pavings

Concrete Slipform Paving – Placer / Spreader Machine
Roads&Pavings

Concrete Slipform Paving
Roads&Pavings

Concrete Slipform Paving – Drilling holes for dowels
Roads&Pavings

Runway Concrete Pavement
Roads&Pavings

Milling / Planing Machine
Roads&Pavings
Used to remove part of the surface of a paved area

Cable Laying
Pipework
Brief Description
132 kVa Cable laying .

Cable Laying
ⓒ David H Moloney
Cable Drum Stand Cable pulled on rollers
Cable Winch
Cable Drum Unloading Cable on rollers Cable Testing prior to Backfilling
Miscellaneous

Horizontal Directional Drilling
Pipework
Brief Description
Horizontal Directional Drilling under a taxiway.
Process
1. A pilot hole id drilled to the designed profile
2. A reamer is pulled back through the hole to enlarge it
3. A pipe string is pulled into the hole.

Horizontal Directional Drilling
Pipework

Micro Tunnelling Sequence David H Moloney
ⓒ David H Moloney
Tunnels

Fencing
Miscellaneous
Brief Description
Fencing.
Sequence of construction;
1. Clear and grade the ground.
2. Fix corner and straining posts.
3. Fix intermediate posts.
4. Fix line wire, chain-link and razor wire.
5. Construct concrete ground beam

Fencing Delivery
Miscellaneous

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

Runway Construction Pavement Details & Mixes
Runway Asphalt Runway Ends Concrete

Concrete Delivery Order - RecordConcrete
Brief Description
It is important to record orders for
concrete deliveries.
The form can be adapted for
other materials e.g.
reinforcement.

Flight CheckTests
Brief Description
Aircraft performing flight checks
on new Instrument Landing
System

Reinforced Wall Construction Sequence
ⓒ David H Moloney
Concrete
Brief Description
The sequence to construct a reinforced concrete wall is as
follows:
Tie the reinforcement.
Erect stop-ends and the wall shutters.
Pour and vibrate the concrete mix.
Remove the shutters after the concrete has hardened.
.
Cycle Time
Pour per Day

Reinforced Wall Construction Sequence
ⓒ David H Moloney
Concrete

Culvert Construction
Concrete
Brief Description
Sequence to construct culvert
with head walls.

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

Excavation for Underground Pump stationEarthworks
Brief Description
Faces of excavation Stepped &
Well-point Dewatering used.

Concrete MixGeneralItems
A concrete mix contains 5 major
elements: cement, water, coarse
aggregates, fine aggregates (sand) and
air in different proportion. Additional
elements such as pozzolanic materials (fly
ash, silica fumes or slag) and chemical
admixtures can also be incorporated to
the mix to increase its properties.

Vibrating Concrete
ⓒ David H Moloney
Concrete

Stakeholders Engagement
Method of Work Plan (MOWP)
A Method of Working Plan (MOWP) is prepared when the normal operation of an aerodrome is
disrupted through aerodrome works and the risk to aircraft operations is increased. Stakeholders
likely to be significantly affected by the proposed works will be given the opportunity to participate
in the planning process.
The MOWP will clearly set out the following: • the scope of work and the stages of carrying out
the work; • how the works are to be carried out and the restrictions on the works organisation; •
how the aircraft operators and pilots will be told, through NOTAM, of the restrictions to aircraft
operations at each stage of the work; • identify any changes necessary to aerodrome markings
and lights as the works progress; • drawings to illustrate work arrangements and changes to
declared distances, taxiing routes, etc.; and • identify persons responsible for the works and those
accountable for ensuring safety of the aerodrome facilities to aircraft operations.
Airport Stakeholders
Operations G.M.
Technical Services G.M
Senior Aviation Manager
Chief Fire Officer
Project Manager
Sr. Maintenance Manager
Operations Reediness Team Leader
Certification & Compliance Manager
Airfield Duty Manager
Airport Duty Manager
HSE Specialist
DGSAS, Director of Airports
DGSAS, Aerodrome Certification
CAA Air Traffic Control –Tower
CAA Chief of Tower
Police
Ground Handling Agent
Airport Refueller Companies

Airplane Wingtip Clearance
Miscellaneous
Brief Description
Regulation distances shown
for wingtip clearance.

Airplane Wingtip Clearance
Miscellaneous

Taxiway Reconstruction Airside
Miscellaneous
Brief Description
Regulations regarding working adjacent to
a live runway.

Taxiway Reconstruction Airside
Miscellaneous

Working Airside to Upgrade Taxiway
Asphalt Pavement Laid on Existing Concrete Pavement Temporary Gate and Fence
Excavation Planing at Runway tie-inFill –Crushed Aggregate Rake sealant
out of Joints

Contractors Temporary Facilities

Temporary Contractors Site Facilities
ⓒ David H Moloney
Brief Description
Site Offices, Camp Accommodation for
1,250 workers, Canteen, Recreation,
Fabrication shops, Stores, Plant Yard. In five
locations along the route.

Welfare Facilities
ⓒ David H Moloney
GeneralItems
Toilets – Washing
Canteen, Drying Room, Toilet & Generator

Site Hoarding examples
ⓒ David H Moloney
GeneralItems

Temporary Fence type 1
ⓒ David H Moloney
GeneralItems
Brief Description
Examples of temporary security
fences that are higher than the
usual

ⓒ David H Moloney
GeneralItems

ⓒ David H Moloney
GeneralItems
Brief Description
Temporary fence on precast beam for airport.

ⓒ David H Moloney
GeneralItems

Dewatering
ⓒ David H Moloney
GeneralItems
Brief Description
Construction dewatering is the removal or drainage of
groundwater and or surface / rain water usually by
pumping to keep the works dry.

Dewatering
ⓒ David H Moloney
GeneralItems
Brief Description
Construction dewatering is the removal or
drainage of groundwater and or surface /
rain water usually by pumping to keep the
works dry.

Dewatering
ⓒ David H Moloney
GeneralItems

Wheel Wash Drive-through
ⓒ David H Moloney
GeneralItems

Wheel Wash Drive-throughGeneralItems

Temporary Electricity Supply & Tower Lights
ⓒ David H Moloney
GeneralItems

Asphalt Batching YardGeneralItems

Concrete Batching Yard 3 Nr MixersGeneralItems

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

Crushed Aggregate Batching PlantGeneralItems

Quarry & Aggregate ProductionGeneralItems

Reinforcement Cutting & Bending Yard David H Moloney
ⓒ David H Moloney
Reinforcement in 12 m lengths. Delivery in 3 ton Bundles Reinforcement cut to length by Shearing Machine
Reinforcement Bent to Shape by Bending Machine Reinforcement that is cut and bent is Bundled for delivery to work site

Reinforcement Cutting & Bending
ⓒ David H Moloney
Concrete

Emergency Phone Numbers & Response

HSE Monitoring & Reporting - Dashboard Dashboard is a single page, graphical representation of
current HSE Issues and historical trends

Personal Protective Equipment (PPE)
Health,Safety&Environment
Personal protective
equipment (PPE) is
protective clothing,
helmets, goggles, or other
garments or equipment
designed to protect the
wearer from injury or
infection

Existing Underground Utilities
ⓒ David H Moloney
Earthworks
Brief Description
Before digging
establish the location
and route of
underground utilities.
Locator to find Utilities
Spray Paint to mark pavement

Existing Underground Utilities & Overhead Cables - Safety Measures
ⓒ David H Moloney
Earthworks

Trench - Safety Measures

Trench - Safety Measures
ⓒ David H Moloney

Safety Training on Site
Miscellaneous The purpose of safety training is to provide the knowledge necessary to
perform a job safely

Safety Training Matrix
Miscellaneous The purpose of safety training is to provide the knowledge necessary to
perform a job safely

Emergency Response Drill
HSE
Drills and exercises are used to rehearse anticipated emergency scenarios

Safety Documents
Safe System of Work.
To provide a safe system of work is a legal requirement. What this means is that before you ask an employee to do a
job. You ensure that he has received training, has the appropriate personal protective equipment, the work area is safe
and he is unlikely to be injured or cause damage by carrying out the assigned task.
Project Management Plan for Health, Safety, Security and Environment. also Known as (HSSE Plan)
The Project HSSE Management Plan details how safety on site will be managed.
Project Procedures for Health, Safety, Security & Environment
Details the safe way to undertake a task
Methods Statements
Are prepared in advance of starting work, to plan a Safe System of Work on site for all activities that carries a risk. The
contents of a Method Statement, typically include:- Scope & Location of the Works, Programme, Roles & Responsibilities
of Staff. Resources, Work Methodologies and Risk Assessment.
Slide 1 of 2

Safety Documents
Safety Risk Assessments
Are prepared to identify and evaluate risks, to adopt control measures to reduce or eliminate risks.
COSHH Sheet
The purpose of the Control Of Substances Hazardous to Health sheet is to identify how to prevent or adequately control
workers exposure to hazardous substances.
Permit to Work.
Is a management system used to control high risk activities by ensuring safety measures are in place prior to starting
work.
Types of work for which permits will be required include:
Excavation and the digging of trenches.
Working at height, including on roofs.
Working in confined spaces, for example entering a manhole.
Hot work, which is welding, soldering or cutting steel with angle grinders or by gas torch.
Slide 2 of 2

Environmentally Friendly Site Air, Noise, Water & Soil Pollution

Hazardous Substances Symbols
COSHH stands for the
Control of Substances
Hazardous to Health
Shown are the new
hazard symbols

Water Pollution PreventionGeneralItems

Segregation of WasteHealth,Safety&Environment
Segregation of waste for proper disposal and
recycling. Less waste goes to landfill and
hazardous waste is treated to make it safe.
Colour Code for Skips & Bins

Putting Waste Concrete to use
ⓒ David H Moloney
Health,Safety&Environment Precast bases for signs and hoarding,
Precast blocks for walls.

Organogram
Brief Description
Shown are the line and
lateral relationships
between the various team
members and their relative
position in the site
organisation.

Staff Directory
Brief Description
List of staff and their
contact details

Daily Work Record
Brief Description
Daily Work Records showing the
allocation of resources, materials and
work activities carried out daily.

Quality Assurance Dashboard Dashboard is a single page, graphical representation of
current statistics and historical trends

Runway Asphalt Pavement - Tests
Roads&Pavings

Runway Concrete Pavement - Tests
Roads&Pavings

Runway Laboratory
Roads&Pavings

Programme & Progress Monitoring

Progress Monthly, Monitoring & Reporting - Dashboard
Dashboard is a single page, graphical representation of current
progress and historical trends

Histogram Charts for Resources & Outputs
Manpower per Discipline
Concrete per Location
Man-hours for each month of the Project
Quantity for each month of the Project
ⓒ David H Moloney
Brief Description
Histograms shows resources etc. for each month of a project.

Programme for Construction
Gantt Charts to plan and schedule projects

Primary Substation-
Chiller Plant
Pump House
IRRIGATIONWATER TANKS
IrrigationPump House-
POTABLE/FIRE WATER TANK
Programme using Timeline & 3D Images
Airport Central Utility Yard

Primary Substation
Chiller Plant
Pump House
IrrigationPump House

Primary Substation-711
Chiller Plant-714
Pump House-
715
716

Chiller Plant-714
Pump House-
715
IRRIGATIONWATER TANK
716

Chiller Plant-714
Pump House-
715
IRRIGATIONWATER TANK
716
POTABLE/FIRE WATER TANK

Airport Roof Truss
ⓒ David H Moloney
StructuralSteel
Brief Description
Roof Truss 190 tonne in weight. Sections welded together on
trestles and the truss is lifted into position.

Airport Roof Truss
StructuralSteel
Roof Truss Sections Roof Truss Sections assembled on trestles
Trusses weigh 190 tonnes Crane Demag CC 8800

Airport – Roof Section Mock-up
StructuralSteel

Airport Piers Roof Frames
StructuralSteel
Sections assembled on trestles

Pedestrian Boarding Bridges & Bridge House
StructuralSteel

Pedestrian Boarding Bridges & Bridge Houses
StructuralSteel
Mock-up

Airport Roof Truss
StructuralSteel

Piers Construction
StructuralSteel

Roof Covering
ⓒ David H Moloney
StructuralSteel
Brief Description
Sequence is
Fix bottom sheet
Fix Vapour barrier
Fix Top Hat section and clips
Fit Insulation
Fix top sheet

View from ATC Tower
Miscellaneous

Tower Construction
Concrete
Brief Description
Air Traffic Control Tower constructed
using a jump-up shutter system.

Production by David H Moloney
My YouTube Channel link: https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ

Runway Construction Methods
© David H Moloney
Earthworks Basecourse Ducts for ground lights
Asphalt Paving Line Marking Flight Check

Heathrow Airport, 3rd Runway Construction
Introduction
This Presentation shows in a straightforward way how a runway
is constructed and how the progress, safety and quality is
monitored and controlled. Also the measures to ensure that
the site is environmentally friendly.
The Presentation can be used to engage Stakeholders and to
get the Site Teams commitment to the programme. Also can be
used as a way to capture and share knowledge.
Presentation can be used for safety and induction Training for
apprentices from the nearby communities that will be
employed on the new infrastructure. The Presentation shows
what to expect prior to stepping onto site and is currently used
for Training in Safety Compliance in airside operations to avoid
safety incidents and accidents
© David H Moloney

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