Hartsfield-Jackson Atlanta International Airport Runway 8R/26L ...

Hartsfield-Jackson Atlanta International Airport
Runway 8R/26L Rehabilitation Project
Presented By:
Quintin Watkins and
Brian Watkinson
Making the Impossible Possible
Through Planning and Teamwork

Presentation Outline
� Project Overview
� Airport Planning Lessons
� Design Lessons
� Procurement Lessons
�� Estimating Considerations
� Construction Pre-planning
� Construction Execution
� Keys to Success

• 5 Runway System
ATL Airfield Overview
• 2 Primary Arrival
Runways
• 2 Primary Departure
Runways
• 1 Mixed Use
• Airfield Capacity
– Arrivals – 126
8L – 45
9R – 36
10 – 45
– Departures – 118
8R – 50
9L – 38
10 – 30
� Runway 8R/26L - 37 years old

Project Overview
10,000 , FT long g x 150 FT wide
� 10,000’ X 150’ Primary Departure Runway
� 3,000’ x 75’ East end of Taxiway E
� 260,000 SY Pavement Replacement
� 16”PCC /6”Cement Treated or Graded Aggregate Base
� New 20” PCC on 2” Asphaltic Cement Concrete Base (ACC)
�� Replaced Pavement Underdrains
� Overlaid Shoulders with ACC
� Replaced Lighting

Project Schedule
� Project Planning Started in 2002
� Construction Started September 8, 2006
� Project completed on November 5, 2006
� 59 ½ Days @ $85 million (ahead of schedule and
$7 million below budget)

Planning Lessons
� Project Timing- 60 Days
� Recent Opening of Runway 10/28 in May 2006
� Coordination with Taxiway V project
– Excavation at end of 8R end
� Fall airline schedule reduction

Runway 8R/26L Rehabilitation - Modeling
� Modeling determined the phasing and
expedited areas

Modeling – Construction Option1 Phase A

Modeling – Construction Option 1 Phase B

Modeling – Construction Option 1 Phase C

Modeling – Construction Option 2

Design Lessons
� On-Call Engineering Consultant
� $2.2 million contract including design and
construction t ti administration
d i i t ti
� 7 month design completed in November 2005
� Included c uded 24/7 / Co Construction st uct o Support Suppo t -1 rep ep on-site o steata at all
times
� Meetings held bi-monthly with DOA design
support staff and impacted stakeholders
� Milestones
�� SD 30% with cost estimate $77 million
� DD 60% Specification Submittal
�� CD 100% with cost estimate $82 million

Design Lessons
� Haul Road parallel to runway
�� Batch Plant Site – Power and Water available
� Security Plan pre-approval
�� Met with Material Suppliers to understand lead
times and supply shortages
� Pavement section test strip
� Utility Locations- If it’s critical find it before the
Contractor

Procurement Lessons
� Design Bid Build
� Pre-Qualify Paving Contractors based on experience, financial
strength (5 Qualified)
� Liquidated Damages – based on Planning model delays
� Nightly Runway Opening Delay - $500/ minute
� Nightly Taxiway Opening Delay - $100/ minute
� Phase 1 (Mobilization)- $ $75,000 /day. Termination if 10 days late
� Phase 2 (Paving and Lighting) - $225,000/day
� Miscellaneous Modification budget established at 2.5% ($2 million)
� Addressed weather delays in contract, during pre-bid and again
after award
� Extended Bid process
�� Requested a detailed schedule and construction method with Bid
� Increased invoicing cycle from once a month to weekly invoicing
� 50% of mobilization paid on first invoice

Procurement Lessons
� PPre-Qualified Q lifi d Bidd Bidders
� 3 of 5 Bidders submitted bids (1 didn’t submit, 2 joint
ventured)
� Bid Bids$67.5 $67 5 M M, $91 $91.5 5 M and d $91 $91.9M 9M
� Met with low bidder to discuss their Bid submittal
� Bid items discussed
� Management of the project
� Schedule
�� Logistics planning
� Traffic control plan
� Resources
� EEssential ti l Subcontractors
S b t t
� Low Bidder found non-responsive and non-responsible
� Awarded to second Bidder after meeting with them
� Issued Notice To Proceed 3 months after determination

Estimating Considerations
� BBatch h plant l site i
� Cement and Flyash Storage
� Material Availability
� Handling of Cement and Flyash
� Concrete Temperature
�� Overall Resources
� People
� Equipment

BATCH PLANT AREA
Large Erie Plant
Small Erie Plant

Large Erie Plant
Plant was purchased for job at cost of $500 $500,000 000 Fun Fun Fact Fact – During the best
24 24-hour hour period over 10,000
tons of aggregate were
received.

Small Erie Plant
Fun Fact – Over 100,000
tons of aggregate were
stockpiled prior to the
startofwork
start of work.

Silos – 14 New and 4 Used
Silos were purchased for the
Silos were purchased for the
job at a cost of $930,000.
Fun Fun Fact Fact – These silos silos can hold
approximately 3000 tons of cement and 1000
tons of flyash. At its peak in a 24 24-hour hour period
over 2500 tons (93 loads) of cement and 625
tons (23 loads) of flyash were off loaded into
these silos.

CEMENT TRAILERS – 15 EA
Fun Fact – Each trailer is
capable of transporting
about 27 tons of cement.
Trailers were purchased for the job
p j
at cost of $870,000.

CYCLONE SYSTEM
Fun Fact – Cyclone system
can push 10 tons of
cement to the plant every
40 seconds. d
Cyclone Air System was
Cyclone Air System was
purchased for the job at a
cost of $450,000.

CHILLERS – 5 Each
The chillers were rented at a
total cost of $90,000.
Fun Fact – Each chiller is
capable of cooling 250 gallons of
water by 10 degrees in I minute.

Ice Makers – 6 Each
Fun Fact – These ice makers
Ice makers were
can produce d 300 t tons of f i ice
purchased for the job at a
per day. That is the
cost of $1,800,000.
equivalent of 60,000 bags.

Paving Equipment Resources
� 2 GGomaco 4000 pavers
� 1 Gomaco 2800 paver
� 1 GGomaco 2600 paver
� 5 Concrete Placers
� 3 Allen Screeds
� 2 Leica wireless
paving system
Fun Fact – The 2800 paver
was purchased for the job at a
cost t of f $540,000. $540 000
Two Leica wireless paving
systems were purchased for
th the job j b at t a cost t of f $219,000 $219 000
per each.

Resources
Resources
•Staff 70
•Craft 230
•200 Legal g hauls
•18 Subcontractors – 250 to 300 craft

Pre-construction Planning Lessons
� EExecutive i Level L l Meetings M i
� 45-day out
�� 30 30-day day out
� 15-day out
� Site SteInvestigation estgato
� What-if Plans
� Test Strips

Executive Level Meetings
•45-day out
•30-day out
•15-day out

What-if Plans
• Anticipate variable and poor soil
conditions

Pre-construction Site Investigation

Pre-construction Site Investigation

Test Strip - Low Slump Concrete

Test Strip - Low Slump Concrete

Test Strip - Hand Pours

Test Strip - Slip Paving

Test Strip - Slip Paving Off of a Header

Test Strip - Electrical

TEST STRIP - Testing

TEST STRIP – Finished Product
Fun Fact – Final cost
of test strip was over
$250,000. ,

DEMOLITION - 29,990 SLABS 6.25’X12.50’
Fun Fun Fact Fact – During the best 24 24-hour hour
period some 4,000 slabs were
removed.

Slab Dumpsite – 14 AC

Fun Facts
� The slabs removed on the job will weigh almost
esabs e o edo t ejob eg a ost
249,000 tons – this equals the weight of 585 fully
loaded Boeing 747’s

Fun Facts
�� The slabs removed on the
job will reach 8.03 miles
high if stacked on top of
one another th (7000’ above b
most airplane cruising
altitudes)
� This equals covering a
football field to a height of
6 stories
t i

ROTOMILL - 261,000 SY

SUBGRADE PREPARATION - 67,800 SY
Over 10,000 CY of low slump
concrete t was required.
i d

UNDERDRAIN - 74,000 LF OF 6”-8” PERF. PIPE
13,400 LF NON PERF. PIPE
Fun Fact – During the best 24-hour 24 hour
period about 6,000 LF of underdrain
was installed installed.

ASPHALT PAVING - 70,300 TONS
Fun Fact – During the best
24 24-hour hour period over 6,000 tons
of asphalt p was p
placed.

Concrete Paving
Fun Fact – During the best
24 24-hour hour period over 10,000 cy
of concrete was placed or an
average of 416 cy/hr cy/hr.

The Job
Progress g

Day 7

Day 14

Day 27

Day 39

Day 54

Opening Day – Day 59 1/2

Final Fun Facts
We Made It!
� At our peak we did $12.5
million of work in a week.
� Th That t is i the th equivalent i l t of f
doing $650 million / year!
�� At peak peak we worked over
18,000 man-hours.
� That is the equivalent q of 450
people based on a 40 hour
work week or 936,000 man-
hours / year!
� Over the 42 days of concrete
paving p g we averaged g 3,650 , cy y
every day or 160 cy every
hour.

Keys to Success
� Complete Team Effort
� Phasing (Aircraft Movement Simulation)
� Detailed Planning (Airport & Contractor)
� Pre-construction Investigation / Test Strips
� Resources
� Quick Issue Resolution
� 24/7 Engineer Support
� Consistent Mix Design g
� Wireless Paving
� Maturity y
Meters

Team Celebration

THANK YOU!
QQuestions? ti ?