ACPA Concrete Pavement Progress - Winter 2022-23

WWW.ACPA.ORG 9 Winter // 2022–23 COMMERCIAL SERVICE AIRPORTS Runway 1L-19R Reconstruction - Phase 1 Kansas City International Airport, Missouri CONTRACTOR: Ideker, Inc.* OWNER: Kansas City Aviation Department ENGINEER: HNTB SILVER Reconstruct Runway 2R/20L Taxiway Hotel & Connectors Nashville, Tennessee CONTRACTOR: Hi-Way Paving, Inc.* OWNER: BNA Nashville International Airport ENGINEER: Garver USA Runway 1L-19R at Kansas City International Airport (MCI) was originally constructed in 1958 and has had several rehabilitation projects over its 60-plus-year life cycle. The existing section that was removed averages a total of 42 inches thick between concrete and asphalt layers. The last major pavement rehabilitation project occurred in 2011, and additional rehabilitations have not proven cost-effective as the pavement experienced more rapid deterioration. Pavement distresses observed in the current section that created foreign object debris potential include joint reflection cracking, longitudinal and transverse cracking, weathering, and raveling. The project was a full-depth reconstruction of the 10,800-foot by 150-foot primary runway. It was completed in two phases over two years. The reconstruction section was 17 inches of concrete, 5 inches of econocrete, 6 inches of aggregate base, and 9 inches of treated subgrade. A total of 103,060 square yards of concrete were used on the runway, and 15,550 square yards were poured for the west runway shoulders. The total cost of the project was $20.4 million, with concrete costs equaling $15.2 million. The $51.7 million project at the Nashville International Airport finished five months early and under budget in spite of restrictions, supply chain disruptions, and rising costs due to COVID-19. Initially constructed in 1980, Runway 2R/20L—the airport’s main landing runway— was deteriorating due to settlement that resulted in constant maintenance, including pressure grouting, panel replacements, spaII repairs, and joint resealing. This project consisted of the full removal and reconstruction of the runway, the full-length parallel taxiway, six taxiway connectors, and blast/turn-around pads at the ends of the taxiways. During the preconstruction process, Hi-Way offered value engineering options to reduce the project duration and cost by altering the phasing and constructing concrete shoulders in lieu of the specified asphalt shoulders due to the high price of FAA-spec asphalt. This change in schedule and shoulder pavement design resulted in savings of $1 million to the airport while reducing the project duration from 20-plus months to 15-plus months. The 16-inch pavement required 262,000 square yards of PCCP. HiWay planned ahead for material shortages by acquiring all of the steel needed for the project months prior to paving and strategically storing it along the 8,000-foot runway to reduce handling costs during construction. GOLD