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Heathrow Airport, 3rd Runway Construction
© David H Moloney
Runway Construction Sequence & Methods
© David H Moloney
Runway Construction Methods
© David H Moloney
Earthworks Basecourse Ducts for ground lights
Asphalt Paving Line Marking Flight Check
M25 Tunnel under Runway Construction Sequence & Methods
© David H Moloney
Culvert under Runway Construction Methods
© David H Moloney
Earthworks Prepare Formation Floor
Walls Roof Backfill
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
Project Execution Plan for Runway Construction 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
10th August 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 & MethodsR
oads &
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© 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 fillE
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Tipper Trucks Unloading
Spreading & Compaction Clay fillE
art
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Backfill TrenchE
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Dozer Pushing ClayE
art
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Dozer Ripping GroundE
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Excavator with Hydraulic RockbreakerE
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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 )E
art
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Mixing Plant
Testing Compaction
Site Trial
Mixing CABCE
art
hw
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Spreading & Compaction CABC ( Crushed aggregate base course )E
art
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Spreading & Compaction CABC ( Crushed aggregate base course ) E
art
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Spreading & Compaction CABC ( Crushed aggregate base course )E
art
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Runway Asphalt PavementR
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Pavin
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Brief Description
Sequence, plant and methods to construct a runway
Prime Coat Site TrialsR
oads &
Pavin
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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 CoatR
oads &
Pavin
gs
Runway Asphalt PavementR
oads &
Pavin
gs
Runway Asphalt PavementR
oads &
Pavin
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Runway Asphalt PavementR
oads &
Pavin
gs
Runway Asphalt PavementR
oads &
Pavin
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Runway Asphalt Pavement - 4 Pavers working togetherR
oads &
Pavin
gs
Runway Asphalt Pavement - 4 Pavers working togetherR
oads &
Pavin
gs
Cutting JointR
oads &
Pavin
gs
Runway Asphalt Pavement - Line & Level R
oads &
Pavin
gs
Checking asphalt level by Dip measurements
String line used for Level & line reference
Runway Asphalt PavementR
oads &
Pavin
gs
Runway Pavement - MarkingR
oads &
Pavin
gs
Runway Pavement – Cleaning surface with rotating water jetsR
oads &
Pavin
gs
Runway Pavement – Cleaning surface with rotating water jetsR
oads &
Pavin
gs
Runway Pavement – Test for Skid Resistance
Roads &
Pavin
gs
Runway Pavement R
oads &
Pavin
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Using the Douglas Mu-Meter continuous friction measuring equipment
Runway Pavement – Test for Smoothness using Rolling Straight Edge
Roads &
Pavin
gs
Runway Pavement – Test for Texture by Sand Patch testR
oads &
Pavin
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Airfield Ground Lights Ducts & ChambersM
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Airfield Ground Lights M
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Airfield Ground Lights Ducts & ChambersM
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Airfield Ground Lights Excavate Trench in CABCM
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Airfield Ground Lights – Concrete DuctsM
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Airfield Ground Lights – Surface Inset LightsM
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Airfield Ground LightsM
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Jig to Level Pot
Airfield Ground Lights - Core drill for Inset LightM
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Airfield Ground Lights Fit Pot with JigM
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Airfield Ground Lights M
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Precast Yard - Chambers M
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Delivery of Precast Chambers M
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Airfield Ground Lights M
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Jointing HDPE Ducts Jointing HDPE Ducts
Precast Chamber Grouting Inset Light Pot
ILS Localiser Antenna & Approach LightsM
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Provides lateral radio guidance to an aircraft approaching and landing on a runway
Approach LightsM
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Approach LightsM
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Used by the pilot to align the aircraft visually with the runway centreline.
ILS Glide Path AntennaM
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Provides radio vertical guidance to an aircraft approaching and landing on a runway
DVOR Ground StationM
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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
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Contains switchgear, protection and control equipment
Airfield Lights - SubstationM
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Contains switchgear, protection and control equipment
Airfield Lights – Taxi Guidance SignsM
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Taxi guidance signs provide direction and information to taxiing aircraft.
Concrete Slipform PavingR
oads &
Pavin
gs
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 PaverSpreader
Texturing & Curing
Concrete Slipform Paving – Texturing MachineR
oads &
Pavin
gs
Concrete Slipform Paving - Slipform MachineR
oads &
Pavin
gs
Concrete Slipform Paving – Placer / Spreader MachineR
oads &
Pavin
gs
Concrete Slipform Paving R
oads &
Pavin
gs
Concrete Slipform Paving R
oads &
Pavin
gs
Concrete Slipform Paving R
oads &
Pavin
gs
Concrete Slipform Paving R
oads &
Pavin
gs
Concrete Slipform Paving – Drilling holes for dowelsR
oads &
Pavin
gs
Concrete Slipform Paving – Drilling holes for dowelsR
oads &
Pavin
gs
Runway Concrete PavementR
oads &
Pavin
gs
Milling / Planing MachineR
oads &
Pavin
gs
Used to remove part of the surface of a paved area
Cable LayingP
ipe
wo
rk
Brief Description
132 kVa Cable laying .
Cable Laying P
ipe
wo
rk
Cable Laying P
ipe
wo
rk
Cable Laying P
ipe
wo
rk
Cable Laying ⓒ David H Moloney
Cable Drum Stand Cable pulled on rollersCable Winch
Cable Drum Unloading Cable on rollers Cable Testing prior to Backfilling
Mis
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Horizontal Directional DrillingP
ipe
wo
rk
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
ipe
wo
rk
Micro TunnellingT
un
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ls
Micro Tunnelling Sequence David H Moloney
ⓒ David H Moloney
Tu
nn
els
FencingM
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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
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FencingM
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FencingM
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FencingM
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Fencing DeliveryM
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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 - RecordC
on
cre
te Brief Description
It is important to record orders for
concrete deliveries.
The form can be adapted for
other materials e.g.
reinforcement.
Flight CheckTe
sts
Brief Description
Aircraft performing flight checks
on new Instrument Landing
System
Concrete
Reinforced Wall Construction Sequence
ⓒ David H Moloney
Co
ncre
te
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
Co
ncre
te
Culvert ConstructionC
on
cre
te
Brief Description
Sequence to construct culvert
with head walls.
Culvert ConstructionC
on
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te
Oil InterceptorM
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Used to capture oil / fuel from leaks or spillages that are washed down drains every time it rains.
Oil InterceptorC
on
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Excavation for Underground Pump stationE
art
hw
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Brief Description
Faces of excavation Stepped &
Well-point Dewatering used.
Concrete MixG
en
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l It
em
s
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
Co
ncre
te
Airside Restrictions
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 ClearanceM
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Brief Description
Regulation distances shown
for wingtip clearance.
Airplane Wingtip ClearanceM
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Taxiway Reconstruction AirsideM
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llan
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Brief Description
Regulations regarding working adjacent to
a live runway.
Taxiway Reconstruction AirsideM
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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
Taxiway Reconstruction AirsideM
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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
Ge
ne
ral It
em
s
Toilets – Washing
Canteen, Drying Room, Toilet & Generator
Site Hoarding examples
ⓒ David H Moloney
Ge
ne
ral It
em
s
Temporary Fence type 1
ⓒ David H Moloney
Ge
ne
ral It
em
s
Brief Description
Examples of temporary security fences that are higher than the usual
Temporary Fence type 1
ⓒ David H Moloney
Ge
ne
ral It
em
s
Temporary Fence type 2
ⓒ David H Moloney
Ge
ne
ral It
em
s
Brief Description
Temporary fence on precast beam for airport.
Temporary Fence type 2
ⓒ David H Moloney
Ge
ne
ral It
em
s
Dewatering
ⓒ David H Moloney
Ge
ne
ral It
em
s
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
Ge
ne
ral It
em
s
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
Ge
ne
ral It
em
s
Wheel Wash Drive-through
ⓒ David H Moloney
Ge
ne
ral It
em
s
Wheel Wash Drive-throughG
en
era
l It
em
s
Temporary Electricity Supply & Tower Lights
ⓒ David H Moloney
Ge
ne
ral It
em
s
Asphalt Batching YardG
en
era
l It
em
s
Asphalt Batching YardG
en
era
l It
em
s
Asphalt Batching YardG
en
era
l It
em
s
Concrete Batching Yard 3 Nr MixersG
en
era
l It
em
s
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
Concrete Batching Yard 3 Nr MixersG
en
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l It
em
s
Crushed Aggregate Batching PlantG
en
era
l It
em
s
Crushed Aggregate Batching PlantG
en
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em
s
Quarry & Aggregate ProductionG
en
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s
Quarry & Aggregate ProductionG
en
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s
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
Co
ncre
te
Setting out & Surveying
Setting out & Surveying
Setting out & Surveying
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
Personal Protective Equipment (PPE)H
ealth,
Safe
ty &
Envir
onm
ent
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
Ea
rth
wo
rks
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
Ea
rth
wo
rks
Trench - Safety Measures H
ealth,
Safe
ty &
Envir
onm
ent
Trench - Safety Measures
ⓒ David H Moloney
Health,
Safe
ty &
Envir
onm
ent
Safety Training on Site M
isce
llan
eo
us
The purpose of safety training is to provide the knowledge necessary to
perform a job safely
Safety Training Matrix M
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The purpose of safety training is to provide the knowledge necessary to
perform a job safely
Emergency Response Drill H
SE
Drills and exercises are used to rehearse anticipated emergency scenarios
Safety DocumentsH
ealth,
Safe
ty &
Envir
onm
ent
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 DocumentsH
ealth,
Safe
ty &
Envir
onm
ent
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 H
ealth,
Safe
ty &
Envir
onm
ent
COSHH stands for the Control of Substances Hazardous to Health
Shown are the new hazard symbols
Water Pollution PreventionG
en
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l It
em
s
Segregation of Waste H
ealth,
Safe
ty &
Envir
onm
ent
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,
Safe
ty &
Envir
onm
ent
Precast bases for signs and hoarding, Precast blocks for walls.
Administration
Organogram
Brief Description
Shown are the line and
lateral relationships
between the various team
members and their relative
position in the site
organisation.
Staff Responsibility Matrix
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.
Quotations Comparison Sheet
Filing System
Quality Assurance
Quality Assurance Dashboard Dashboard is a single page, graphical representation of
current statistics and historical trends
Runway Asphalt Pavement - TestsR
oads &
Pavin
gs
Quality Assurance Tests
Runway Concrete Pavement - TestsR
oads &
Pavin
gs
Runway LaboratoryR
oads &
Pavin
gs
Laboratory
ⓒ David H Moloney
Asp
ha
lt P
avin
g
Programme & Progress Monitoring
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
ⓒ David H Moloney
Brief Description
Histograms shows resources etc. for each month of a project.
Plant & Equipment List & Worker’s Job Titles
ⓒ David H Moloney
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
Chiller PlantPump House
Irrigation Pump House
Primary Substation-711
Chiller Plant-714Pump House-715
Irrigation Pump House-716
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
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
Primary Substation-711
Chiller Plant-714Pump House-715
IRRIGATION WATER TANK
Irrigation Pump House-716
POTABLE/FIRE WATER TANK
Miscellaneous
Structural Steel
Airport Roof Truss
ⓒ David H Moloney
Str
uctu
ral S
tee
l
Brief Description
Roof Truss 190 tonne in weight. Sections welded together on
trestles and the truss is lifted into position.
Airport Roof TrussS
tru
ctu
ral S
tee
l
Roof Truss Sections Roof Truss Sections assembled on trestles
Trusses weigh 190 tonnes Crane Demag CC 8800
Airport – Roof Section Mock-up S
tru
ctu
ral S
tee
l
Airport Piers Roof Frames S
tru
ctu
ral S
tee
l
Sections assembled on trestles
Pedestrian Boarding Bridges & Bridge House S
tru
ctu
ral S
tee
l
Pedestrian Boarding Bridges & Bridge HouseS
tru
ctu
ral S
tee
l
Pedestrian Boarding Bridges & Bridge HousesS
tru
ctu
ral S
tee
l
Mock-up
Airport Roof TrussS
tru
ctu
ral S
tee
l
Airport Roof TrussS
tru
ctu
ral S
tee
l
Piers ConstructionS
tru
ctu
ral S
tee
l
Piers ConstructionS
tru
ctu
ral S
tee
l
Roof Covering
ⓒ David H Moloney
Str
uctu
ral S
tee
l
Brief Description
Sequence is
Fix bottom sheet
Fix Vapour barrier
Fix Top Hat section and clips
Fit Insulation
Fix top sheet
Roof Covering
ⓒ David H Moloney
Str
uctu
ral S
tee
l
Roof Covering
ⓒ David H Moloney
Str
uctu
ral S
tee
l
Roof Covering
ⓒ David H Moloney
Str
uctu
ral S
tee
l
View from ATC TowerM
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View from ATC TowerM
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View from ATC TowerM
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Tower ConstructionC
on
cre
te
Brief Description
Air Traffic Control Tower constructed
using a jump-up shutter system.
ATC Tower CladdingC
on
cre
te
Production by David H Moloney
My YouTube Channel link: https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ
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