Airport Construction

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

David H Moloney

1st August 2016

Brief Description

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

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.

YouTube https://youtu.be/LY4gXkUgK_Y

Table of Contents

General Items

Contractor’s Temporary Site Facilities

Genera

l Item

Brief Description

Contractors Site facilities comprise:Offices, Canteens, Toilets, Drying Rooms, Stores, Plant Yard, generators and Workshops.

Contractor’s Temporary Site Facilities

Genera

l Item

To see animations and clips, see my YouTube Film

Contractor’s Camp for 8,000 persons

Genera

l Item

Sheet Pile Temporary Shaft

Genera

l Item

Brief Description

Sheet Pile Temporary shaft is used to enable an excavation for a deep structure.The construction sequence is:Install sheet-piles.Excavate and install bracing.Excavate to final level.Construct concrete structure.Backfill, remove bracing and sheet-piles

Sheet pile Temporary Shaft

Genera

l Item

3D Animation to show Sequence

Dewatering

Genera

l Item

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

Genera

l Item

Dewatering by Wellpoints

Genera

l Item

Water Pollution Prevention

Genera

l Item

Brief Description

Pumped and rain water that is contaminated with clay and

silt needs to be treated prior to discharge from site.

Settlement ponds and settlement tanks are two methods

Dewatering by Settlement Lagoon

Genera

l Item

Dust Suppression

Genera

l Item

Temporary Fence type 1

Genera

l Item

Brief Description

Examples of temporary security fences that are higher than the usual

Genera

l Item

Genera

l Item

Brief Description

Temporary fence on precast beam for airport.

Genera

l Item

Site Hoarding examples

Genera

l Item

FalseworkG

l Item

Brief Description

Falsework to support Bridge deck formwork

Climbing Tower Cranes

Brief Description

A climbing tower crane lifts itself up using a climbing

attachment with hydraulic jacks that surrounds the mast.

The climbing attachment lifts itself up off the erected mast

and inserts a new mast section.

Rail mounted Tower Cranes layout plan and photographs for

airport passenger terminal building, showing the tower

cranes locations, rail track travel range and working area

coverage.

Genera

l Item

Climbing Tower CranesM

iscella

Climbing Tower CranesG

l Item

Tower Cranes LayoutG

l Item

Tower Cranes on RailsG

l Item

Staff Offices for Departments

Department Functions

Planning Planning & Progress Monitoring

HSSE Health, Safety, Security & Environmental

Quality Assurance Quality Control

Procurement Materials & Subcontractors

Engineering Shop drawings & submissions

Quantity Surveying Monthly & final accounts

Document Control Distribution of Construction Information to Site Team

Plant & Equipment Hiring, Fuelling & Maintenance of Plant

I.T. Computers, software & Internet

Administration Payments

Human Resources

Site LaboratoryG

l item

Traffic Management

Genera

l Item

Brief Description

Traffic management plans are necessary when working on or beside roads

Traffic Management - Realign Motorway under new Bridges

Genera

l Item

Traffic Management - Realign Motorway under new Bridges

Genera

l Item

Traffic Management – Divert Live Traffic onto Realigned Carriageway

Genera

l Item

Temporary Site Entrance

Genera

l Item

Temporary Roads & Entrances

Genera

l Item

Weighbridge & Sheeting Access

Genera

l Item

Wheel Wash Drive-through

Genera

l Item

Wheel Wash Drive-throughG

l Item

Stores for Materials

Genera

l Item

Stores for Materials

Genera

l Item

Site Layout & Locations of Temporary Facilities

Genera

l Item

Temporary Electricity Supply & Tower Lights

Genera

l Item

Welfare Facilities

Genera

l Item

Toilets – Washing

Canteen, Drying Room, Toilet & Generator

Geotechnical

Vibro Compaction - Sequence, Plant & Methods

Brief Description

Vibro compaction is used to compact granular

ground to improve its load bearing capacity and

reduces the seismic liquefaction potential. Used

for the Palm Islands in Dubai.

A vibrator suspended from a crane is used and

inserted to a triangular grid pattern.

Vibro Compaction - Sequence, Plant & Methods

Stone Columns ⓒ David H MoloneyG

Brief Description

Stone columns are used to improve the load

bearing capacity of ground.

Top feed vibrators suspended from an excavator or

crane along with loading shovels are used.

The stone columns are constructed to a triangular

grid pattern.

Stone Columns

Earthworks

Much Shifting

Brief Description

Muck Shifting is the process of moving

large quantities of soil and rock. Eart

Excavate & Load, Cart, Tip & Return

Brief Description

Cycle Time for 7km haulage distance using an Excavator 45 tonne weight and Dumper with a 40 tonne capacity, the cycle time is 34 minutes

7 minutes

14 minutes

3 minutes

14 minutes 7 km

Spreading & CompactionE

Rock - Excavability

Brief Description

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.

Rock-breakingE

Rock Drilling & Blasting – Road CutE

Mass Haul DiagramE

Brief Description

Shows the quantities and location of

excavation and fill quantities for

motorway.

Excavation for Underground Pump stationE

Brief Description

Faces of excavation Battered &

Well-point Dewatering used.

Excavation for Trenches with Stepped FacesE

Excavation for Trenches with Battered FacesE

Backfill TrenchE

Crushed Aggregate Base CourseE

Brief Description

Crushed Aggregate Base Course

CABC mixing and Laying

CABC ( Crushed aggregate base course )E

Mixing Plant

Testing Compaction

Mixing CABCE

Spreading & Compaction CABCE

Spreading & Compaction CABC ( Crushed aggregate base course )E

Spreading & Compaction CABCE

Piling

Piling Construction - Plant & Methods

Brief Description

Piling Plant, Equipment and Material;

Crawler Crane, Piling Hammer, Temporary Casing,

Piling Rig, Concrete Pump, Concrete Mixer Trucks,

Tremie Pipe and Reinforcement Cage

Piling Construction - Plant, Methods & SequenceP

Piling Construction - Plant & MethodsP

Piling Construction - Vertical PilesP

Piling Construction - Raking PilesP

Pile Load Test

Brief Description

A jack is used to load the pile in steps and

gauges measure any settlement.

Pile Load Test

Concrete

Concrete Full Scale Trial Castings of Pier

Brief Description

The full-scale trial casting(s) shall

demonstrate/document that all

requirements to the concrete and the

execution of the work are fulfilled

simultaneously using the actual

methods and performed by personnel as

for the future production.

Concre

BIM 3D Model Shutter Fibreglass

Concrete Full Scale Trial Castings of Bridge Deck

Brief Description

The full-scale trial casting(s) shall

demonstrate/document that all

requirements to the concrete and the

execution of the work are fulfilled

simultaneously using the actual

methods and performed by personnel as

for the future production.

Concre

Fresh Concrete Properties Tests

Air Content, Consistence, Density, Initial and Final Setting Time, Temperature

and Bleeding

Chloride Ion Content

Hardening and Hardened Concrete Properties Tests:

Density and Compressive Strength for 1, 3, 7, 14 and 28 Days

Concrete Core Compressive Strength

Tensile Splitting Strength

Modulus of Elasticity

Heat Development

Chloride Migration Coefficient (28 Days)

Reinforcement Cover Measurement Survey

Concrete Batching Plant David H Moloney

Brief Description

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.

Concre

Concrete Batching Plant

Concre

Concrete Batching Plant

Concre

Concrete Batching Plant – Computer Controlled

Concre

Concrete Batching Plant - Liebherr Betomix AnimationC

Concrete Batching Plant David H Moloney

Brief Description

The mixing is computer controlled

and has a dynamic screen display,

showing the process. The material

storage capacity is, to match two

days concrete production.

Concre

Quarry & Aggregate Production

Concre

Brief Description

Quarry and Aggregate Production. Rock is

blasted free from a quarry face and fragmented.

The blasted rock is crushed and screened to

produce different size ranges of aggregates

Quarry & Aggregate Production

Concre

Quarry - Drilling Holes for Explosives

Concre

Quarry - Placing Explosives in Holes

Concre

Quarry - Blasting

Concre

Aggregate Production

Concre

Capacity 300 tonnes per hour

Quarry Plant & OutputsC

Reinforcement Cutting & Bending Yard

Concre

Brief Description

Reinforcement in 12 m lengths. Delivery in 3 ton Bundles

Reinforcement Cutting & Bending

Concre

Reinforcement Cutting & Bending

Concre

Reinforcement Cutting & Bending Yard 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

Concre

Precast Yard

Concre

Reinforced Wall Construction Sequence

Concre

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

Concre

Reinforced Structure Construction Sequence

Concre

Brief Description

The general sequence to construct a reinforced concrete tank

is as follows-

1. Construct the floor and wall panels in a hit and miss pattern.

2. Construct the floor and wall corners and T shape panels.

3. Construct the roof working outwards from the back.

Reinforced Structure Construction Sequence

Concre

Reinforced Construction Tank, Construction Sequence David H Moloney

Concre

Bridge & Post-tensioningC

Brief Description

The sequence to post-tension a bridge

deck is as follows;

Fix the ducts and anchorages.

Install the stressing strand.

Concrete the deck.

Stress the strands and lock at

anchorages.

Grout the ducts.

Bridges on ProjectC

Bridge & Post-tensioningC

Bridge Concrete DeckC

Bridge Post Tensioning Deck – Install StrandC

Bridge Post Tensioning DeckC

Bridge Construction Sequence David H Moloney

Concre

Bridge Construction Stages, Images & TimelineC

Tower ConstructionC

Brief Description

Air Traffic Control Tower constructed

using a jump-up shutter system.

Tower Construction Climbing ShutterC

Cycle Time 3 Days

ATC Tower CladdingC

Culvert ConstructionC

Brief Description

Sequence to construct culvert

with head walls.

Culvert ConstructionC

Oil InterceptorM

iscella

Oil InterceptorC

Waterproofing Spray on SystemM

iscella

Waterproofing Spray on TestsM

iscella

Structural Steel & Miscellaneous

Airport Roof Truss

Brief Description

Roof Truss 190 tonne in weight. Sections welded together on

trestles and the truss is lifted into position.

Airport Roof TrussS

tructu

Roof Truss Sections Roof Truss Sections assembled on trestles

Trusses weigh 190 tonnes Crane Demag CC 8800

Airport – Roof Section Mock-up S

tructu

Airport Piers Roof Frames S

tructu

Sections assembled on trestles

Pedestrian Boarding Bridges & Bridge House S

tructu

Pedestrian Boarding Bridges & Bridge HouseS

tructu

Pedestrian Boarding Bridges & Bridge HousesS

tructu

Mock-up

Airport Roof TrussS

tructu

Airport Roof TrussS

tructu

Piers ConstructionS

tructu

Piers ConstructionS

tructu

Roof Covering

Brief Description

Sequence is

Fix bottom sheet

Fix Vapour barrier

Fix Top Hat section and clips

Fit Insulation

Fix top sheet

Roof Covering

View from ATC TowerM

iscella

Steel Building Multi-storey

Brief Description

Sequence to erect a structural steel multi storey

building.

Steel Building Multi-storey

Structural Steel Building Multi Storey

Step 1 Set-out Grid Lines Step 2 Holding Down Bolts Step 3 Erect 1st level use core for stability

Step 4 Complete 1st Level Step 5 Erect following Levels Step 6 Plumb & Align Structure

3D images to show Construction Sequence.

Steel Building Single Storey

Brief Description

Sequence to erect a structural

steel single storey portal building.

Steel Building Single Storey

Structural Steel Building Single Storey

3D images to show Construction Sequence.

Step 1 Set-out Grid Lines Step 2 Holding Down Bolts Step 3 Erect 1st Bay

Step 4 Erect 2nd Bay Step 5 Erect following Bays

Airport Fuel Farm

Steel Storage Tank

Brief Description

Sequence and methods to construct a

steel circular tank.

Steel Storage Tank

Steel Circular Storage Tank – Construction ⓒ David H MoloneyS

tructu

Fireproofing Steel

Brief Description

Wet Mix Spray-Applied Fire Resistive Gypsum- based

Material to underside of roof deck – Site Trial

Fireproofing Steel Deck TrialS

tructu

Pipework

Central Utility YardM

iscella

Chiller Building M

iscella

Provides chilled water for Air Conditioning

Chiller Plant M

iscella

BIMChilled Water Storage Tank

Chiller Building Cooling Towers

Chiller Building M

iscella

Chiller Building

Pipe Spools FabricationP

Brief Description

Spools are fabricated from pipes and fittings .

Spool Fabrication on site P

Pipe Spool Fabrication Workshop P

Spool Fabrication - Pipe Rolling & Cutting Table P

Spool Fabrication Spool Rolling & Welding P

W. Soule & Company USA

Spool Fabrication - Automatic Welding with Pipe RollingP

W. Soule & Company USA

Welding Positioner / TurntableP

Anyeke.com.my

Post Weld Heat Treatment

Non Destructive Testing

Fit-up

Blasting

Painting

Spool Fabrication StepsP

Cable LayingP

Brief Description

132 kVa Cable laying .

Cable Laying P

Cable Laying ⓒ David H Moloney

Cable Drum Stand Cable pulled on rollersCable Winch

Cable Drum Unloading Cable on rollers Cable Testing prior to Backfilling

Transformers & GeneratorsM

iscella

Generator & Primary Substation Building M

iscella

Fuel Pipeline P

Fuel Hydrant Pipeline P

Double Jointing Welding i.e. joining two pipes

Welding Pipe Joint in Trench Welding

Valve Chamber Fuel HydrantDouble Block & Bleed Valve

Chilled Water Pipelines P

Chilled Water PipelinesDelivery & Return

Pipe has Insulation & Seal Coat Valve ChamberWelding & Insulation to Joint

Pipes and Welding Pits Pipeline & Chamber

Roads & Pavings

Asphalt Batching YardR

Brief Description

Asphalt Batching Yard

Capacity of main batching plant is

250 tonnes per hour .

Asphalt Batching YardR

Road Construction

Brief Description

Sequence, methods and plant to construct a

motorway on a high embankment

Road ConstructionR

Runway Asphalt PavementR

oads &

Brief Description

Sequence, plant and methods to construct a runway

oads &

Prime Coat Site TrialsR

oads &

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.

oads &

Runway Asphalt Pavement - 4 Pavers working togetherR

oads &

Runway Asphalt Pavement - TestsR

oads &

Asphalt Pavement - 4 Pavers in EchelonR

oads &

Brief Description

4 pavers used to minimise lengths of cold joints

Asphalt Pavement - 4 Pavers in EchelonR

oads &

Concrete Slipform PavingR

oads &

Brief Description

Slipform Airport Concrete paving.

Slipform Concrete PaverSpreader

Texturing & Curing

Concrete Slipform Paving – Texturing MachineR

oads &

Concrete Slipform Paving - Slipform MachineR

oads &

Concrete Slipform Paving – Placer / Spreader MachineR

oads &

Concrete Slipform Paving R

oads &

Concrete Slipform Paving – Drilling holes for dowelsR

oads &

Concrete Slipform Paving – Drilling holes for dowelsR

oads &

Runway Concrete PavementR

oads &

Runway Concrete Pavement - TestsR

oads &

Runway Pavement - MarkingR

oads &

Milling / Planing MachineR

oads &

Runway Pavement – Cleaning surface with rotating water jetsR

oads &

Runway Pavement – Cleaning surface with rotating water jetsR

oads &

Flight CheckTests

Brief Description

Aircraft performing flight checks

on new Instrument Landing

System

Twin Tunnels single track with Cross passages at 250m intervals for emergency evacuation

Tunnels in rock to avoid ground & building settlement. Depth 25 metres on average

Rail Underground

Rail UndergroundC

Install Traffic Control Fencing & Welfare Facilities Divert Underground Utilities Excavate

Prepare Formation Reinforcement & Rails Paving

Paving Information Sign Trams in Operation Trams in Operation

Reinforcement & Rails

Rail Surface

Rail ViaductC

Brief Description

Shown is the construction of a light rail viaduct where

an overhead gantry was used to lift and place the

precast concrete viaduct segments.

Rail ViaductC

Tunnels

Micro Tunnelling

Brief Description

Micro tunnelling is used to dig small tunnels

where a tunnelling boring machine is

controlled from a cabin at ground level

Tunnels

Micro TunnellingT

unnels

Micro Tunnelling Sequence David H Moloney

Tunnels

Pipe-jackingP

Brief Description

Method for pipe-jacking

The pipes are assembled in the access

shaft and are pushed using a hydraulic

jack..

Pipe-jackingP

Horizontal Directional DrillingP

Brief Description

Horizontal Directional Drilling under a taxiway.

Process

1. A pilot hole id drilled to the designed profile

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

3. A pipe string is pulled into the hole.

Horizontal Directional DrillingP

Survey & Setting Out

Setting out & Surveying

Miscellaneous Works

FencingM

iscella

Brief Description

Fencing.

Sequence of construction;

1. Clear and grade the ground.

2. Fix corner and straining posts.

3. Fix intermediate posts.

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

5. Construct concrete ground beam

FencingM

iscella

FencingM

iscella

FencingM

iscella

FencingM

iscella

Airplane Wingtip ClearanceM

iscella

Brief Description

Regulation distances shown

for wingtip clearance.

Airplane Wingtip ClearanceM

iscella

Taxiway Reconstruction AirsideM

iscella

Brief Description

Regulations regarding working adjacent to

a live runway.

iscella

Airfield Ground Lights M

iscella

Airfield Ground Lights Ducts & ChambersM

iscella

Airfield Ground Lights Ducts & ChambersM

iscella

Airfield Ground Lights Excavate Trench in CABCM

iscella

Airfield Ground Lights – Concrete DuctsM

iscella

Airfield Ground LightsM

iscella

Airfield Ground LightsM

iscella

Jig to Level Pot

Airfield Ground Lights - Core drill for LightM

iscella

Airfield Ground Lights Fit Pot with JigM

iscella

Jointing HDPE Ducts Jointing HDPE Ducts

Precast Chamber Grouting Inset Light Pot

ILS Localiser Antenna & Approach LightsM

iscella

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

Approach LightsM

iscella

Approach LightsM

iscella

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

ILS Glide Path AntennaM

iscella

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

DVOR Ground StationM

iscella

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

Airfield Lights - SubstationM

iscella

Contains switchgear, protection and control equipment

Airfield Lights – Taxi Guidance SignsM

iscella

Taxi guidance signs provide direction and information to taxiing aircraft.

Administration

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

progress and historical trends

Histogram Charts for Resources & Outputs

Manpower per Discipline

Concrete per Location

Man-hours for each month of the Project

Quantity for each month of the Project

Brief Description

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

Plant & Equipment List & Worker’s Job Titles

Daily Work Record

Brief Description

Daily Work Records showing the

allocation of resources, materials and

work activities carried out daily.

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

Time Chainage Diagram

Brief Description

The chart has two axis: one for time and the other for location

A legend explains meaning of the colours, symbols and line types

Legend

Filing System

Safety & Environmental

Emergency Phone Numbers & Response

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

current HSE Issues and historical trends

Site Safety Posters examples

Safety Precautions

Existing Underground Utilities

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

Trench - Safety Measures H

ealth,

Environm

Trench - Safety Measures

Health,

Environm

Safety Training on Site M

iscella

Safety Training M

iscella

Mock Fire Accident Drill M

iscella

Environmentally Friendly Site Air, Noise, Water & Soil Pollution

Water Pollution PreventionG

l Item

Concrete Washout & Settlement TanksG

l Item

Segregation of Waste H

ealth,

Environm

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

Quality Assurance

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

current statistics and historical trends

Runway Asphalt Pavement - TestsR

oads &

Runway Concrete Pavement - TestsR

oads &

Runway Pavement – Test for Skid Resistance

Roads &

Runway Pavement R

oads &

Using the Douglas Mu-Meter continuous friction measuring equipment

Runway Pavement – Test for Smoothness using Rolling Straight Edge

Roads &

Runway Pavement – Test for Texture by Sand Patch testR

oads &

Programme

Programme for Construction

Gantt Charts to plan and schedule projects

Primary Substation-

Chiller Plant

Pump House

IRRIGATION WATER TANKS

Irrigation Pump House-

POTABLE/FIRE WATER TANK

Programme using Timeline & 3D Images

Airport Central Utility Yard

Pump House

Piling

Primary Substation-711

Chiller Plant-714Pump House-715

IRRIGATION WATER TANK

Irrigation Pump House-716

Primary Substation-711

Chiller Plant-714Pump House-715

IRRIGATION WATER TANK

Irrigation Pump House-716

POTABLE/FIRE WATER TANK

Programme Time Chainage

Programme Time ChainageThe chart has two axis: one for time and the other for location

A legend explains meaning of the colours, symbols and line types

Group Photos

Production by David H Moloney

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

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