Hartsfield-Jackson Atlanta International Airport Runway 8R/26L ...
Hartsfield-Jackson Atlanta International Airport Runway 8R/26L ... 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
- Page 2 and 3: Presentation Outline � Project Ov
- Page 4 and 5: Project Overview 10,000 , FT long g
- Page 6 and 7: Planning Lessons � Project Timing
- Page 8 and 9: Modeling - Construction Option1 Pha
- Page 10 and 11: Modeling - Construction Option 1 Ph
- Page 12 and 13: Design Lessons � On-Call Engineer
- Page 14 and 15: Procurement Lessons � Design Bid
- Page 16 and 17: Estimating Considerations � BBatc
- Page 18 and 19: Large Erie Plant Plant was purchase
- Page 20 and 21: Silos - 14 New and 4 Used Silos wer
- Page 22 and 23: CYCLONE SYSTEM Fun Fact - Cyclone s
- Page 24 and 25: Ice Makers - 6 Each Fun Fact - Thes
- Page 26 and 27: Resources Resources •Staff 70 •
- Page 28 and 29: Executive Level Meetings •45-day
- Page 30 and 31: Pre-construction Site Investigation
- Page 32 and 33: Test Strip - Low Slump Concrete
- Page 34 and 35: Test Strip - Hand Pours
- Page 36 and 37: Test Strip - Slip Paving Off of a H
- Page 38 and 39: TEST STRIP - Testing
- Page 40 and 41: DEMOLITION - 29,990 SLABS 6.25’X1
- Page 42 and 43: Fun Facts � The slabs removed on
- Page 44 and 45: ROTOMILL - 261,000 SY
- Page 46 and 47: UNDERDRAIN - 74,000 LF OF 6”-8”
- Page 48 and 49: Concrete Paving Fun Fact - During t
- Page 50 and 51: Day 7
<strong>Hartsfield</strong>-<strong>Jackson</strong> <strong>Atlanta</strong> <strong>International</strong> <strong>Airport</strong><br />
<strong>Runway</strong> <strong>8R</strong>/<strong>26L</strong> Rehabilitation Project<br />
Presented By:<br />
Quintin Watkins and<br />
Brian Watkinson<br />
Making the Impossible Possible<br />
Through Planning and Teamwork
Presentation Outline<br />
� Project Overview<br />
� <strong>Airport</strong> Planning Lessons<br />
� Design Lessons<br />
� Procurement Lessons<br />
�� Estimating Considerations<br />
� Construction Pre-planning<br />
� Construction Execution<br />
� Keys to Success
• 5 <strong>Runway</strong> System<br />
ATL Airfield Overview<br />
• 2 Primary Arrival<br />
<strong>Runway</strong>s<br />
• 2 Primary Departure<br />
<strong>Runway</strong>s<br />
• 1 Mixed Use<br />
• Airfield Capacity<br />
– Arrivals – 126<br />
8L – 45<br />
9R – 36<br />
10 – 45<br />
– Departures – 118<br />
<strong>8R</strong> – 50<br />
9L – 38<br />
10 – 30<br />
� <strong>Runway</strong> <strong>8R</strong>/<strong>26L</strong> - 37 years old
Project Overview<br />
10,000 , FT long g x 150 FT wide<br />
� 10,000’ X 150’ Primary Departure <strong>Runway</strong><br />
� 3,000’ x 75’ East end of Taxiway E<br />
� 260,000 SY Pavement Replacement<br />
� 16”PCC /6”Cement Treated or Graded Aggregate Base<br />
� New 20” PCC on 2” Asphaltic Cement Concrete Base (ACC)<br />
�� Replaced Pavement Underdrains<br />
� Overlaid Shoulders with ACC<br />
� Replaced Lighting
Project Schedule<br />
� Project Planning Started in 2002<br />
� Construction Started September 8, 2006<br />
� Project completed on November 5, 2006<br />
� 59 ½ Days @ $85 million (ahead of schedule and<br />
$7 million below budget)
Planning Lessons<br />
� Project Timing- 60 Days<br />
� Recent Opening of <strong>Runway</strong> 10/28 in May 2006<br />
� Coordination with Taxiway V project<br />
– Excavation at end of <strong>8R</strong> end<br />
� Fall airline schedule reduction
<strong>Runway</strong> <strong>8R</strong>/<strong>26L</strong> Rehabilitation - Modeling<br />
� Modeling determined the phasing and<br />
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<br />
� On-Call Engineering Consultant<br />
� $2.2 million contract including design and<br />
construction t ti administration<br />
d i i t ti<br />
� 7 month design completed in November 2005<br />
� Included c uded 24/7 / Co Construction st uct o Support Suppo t -1 rep ep on-site o steata at all<br />
times<br />
� Meetings held bi-monthly with DOA design<br />
support staff and impacted stakeholders<br />
� Milestones<br />
�� SD 30% with cost estimate $77 million<br />
� DD 60% Specification Submittal<br />
�� CD 100% with cost estimate $82 million
Design Lessons<br />
� Haul Road parallel to runway<br />
�� Batch Plant Site – Power and Water available<br />
� Security Plan pre-approval<br />
�� Met with Material Suppliers to understand lead<br />
times and supply shortages<br />
� Pavement section test strip<br />
� Utility Locations- If it’s critical find it before the<br />
Contractor
Procurement Lessons<br />
� Design Bid Build<br />
� Pre-Qualify Paving Contractors based on experience, financial<br />
strength (5 Qualified)<br />
� Liquidated Damages – based on Planning model delays<br />
� Nightly <strong>Runway</strong> Opening Delay - $500/ minute<br />
� Nightly Taxiway Opening Delay - $100/ minute<br />
� Phase 1 (Mobilization)- $ $75,000 /day. Termination if 10 days late<br />
� Phase 2 (Paving and Lighting) - $225,000/day<br />
� Miscellaneous Modification budget established at 2.5% ($2 million)<br />
� Addressed weather delays in contract, during pre-bid and again<br />
after award<br />
� Extended Bid process<br />
�� Requested a detailed schedule and construction method with Bid<br />
� Increased invoicing cycle from once a month to weekly invoicing<br />
� 50% of mobilization paid on first invoice
Procurement Lessons<br />
� PPre-Qualified Q lifi d Bidd Bidders<br />
� 3 of 5 Bidders submitted bids (1 didn’t submit, 2 joint<br />
ventured)<br />
� Bid Bids$67.5 $67 5 M M, $91 $91.5 5 M and d $91 $91.9M 9M<br />
� Met with low bidder to discuss their Bid submittal<br />
� Bid items discussed<br />
� Management of the project<br />
� Schedule<br />
�� Logistics planning<br />
� Traffic control plan<br />
� Resources<br />
� EEssential ti l Subcontractors<br />
S b t t<br />
� Low Bidder found non-responsive and non-responsible<br />
� Awarded to second Bidder after meeting with them<br />
� Issued Notice To Proceed 3 months after determination
Estimating Considerations<br />
� BBatch h plant l site i<br />
� Cement and Flyash Storage<br />
� Material Availability<br />
� Handling of Cement and Flyash<br />
� Concrete Temperature<br />
�� Overall Resources<br />
� People<br />
� Equipment
BATCH PLANT AREA<br />
Large Erie Plant<br />
Small Erie Plant
Large Erie Plant<br />
Plant was purchased for job at cost of $500 $500,000 000 Fun Fun Fact Fact – During the best<br />
24 24-hour hour period over 10,000<br />
tons of aggregate were<br />
received.
Small Erie Plant<br />
Fun Fact – Over 100,000<br />
tons of aggregate were<br />
stockpiled prior to the<br />
startofwork<br />
start of work.
Silos – 14 New and 4 Used<br />
Silos were purchased for the<br />
Silos were purchased for the<br />
job at a cost of $930,000.<br />
Fun Fun Fact Fact – These silos silos can hold<br />
approximately 3000 tons of cement and 1000<br />
tons of flyash. At its peak in a 24 24-hour hour period<br />
over 2500 tons (93 loads) of cement and 625<br />
tons (23 loads) of flyash were off loaded into<br />
these silos.
CEMENT TRAILERS – 15 EA<br />
Fun Fact – Each trailer is<br />
capable of transporting<br />
about 27 tons of cement.<br />
Trailers were purchased for the job<br />
p j<br />
at cost of $870,000.
CYCLONE SYSTEM<br />
Fun Fact – Cyclone system<br />
can push 10 tons of<br />
cement to the plant every<br />
40 seconds. d<br />
Cyclone Air System was<br />
Cyclone Air System was<br />
purchased for the job at a<br />
cost of $450,000.
CHILLERS – 5 Each<br />
The chillers were rented at a<br />
total cost of $90,000.<br />
Fun Fact – Each chiller is<br />
capable of cooling 250 gallons of<br />
water by 10 degrees in I minute.
Ice Makers – 6 Each<br />
Fun Fact – These ice makers<br />
Ice makers were<br />
can produce d 300 t tons of f i ice<br />
purchased for the job at a<br />
per day. That is the<br />
cost of $1,800,000.<br />
equivalent of 60,000 bags.
Paving Equipment Resources<br />
� 2 GGomaco 4000 pavers<br />
� 1 Gomaco 2800 paver<br />
� 1 GGomaco 2600 paver<br />
� 5 Concrete Placers<br />
� 3 Allen Screeds<br />
� 2 Leica wireless<br />
paving system<br />
Fun Fact – The 2800 paver<br />
was purchased for the job at a<br />
cost t of f $540,000. $540 000<br />
Two Leica wireless paving<br />
systems were purchased for<br />
th the job j b at t a cost t of f $219,000 $219 000<br />
per each.
Resources<br />
Resources<br />
•Staff 70<br />
•Craft 230<br />
•200 Legal g hauls<br />
•18 Subcontractors – 250 to 300 craft
Pre-construction Planning Lessons<br />
� EExecutive i Level L l Meetings M i<br />
� 45-day out<br />
�� 30 30-day day out<br />
� 15-day out<br />
� Site SteInvestigation estgato<br />
� What-if Plans<br />
� Test Strips
Executive Level Meetings<br />
•45-day out<br />
•30-day out<br />
•15-day out
What-if Plans<br />
• Anticipate variable and poor soil<br />
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<br />
Fun Fact – Final cost<br />
of test strip was over<br />
$250,000. ,
DEMOLITION - 29,990 SLABS 6.25’X12.50’<br />
Fun Fun Fact Fact – During the best 24 24-hour hour<br />
period some 4,000 slabs were<br />
removed.
Slab Dumpsite – 14 AC
Fun Facts<br />
� The slabs removed on the job will weigh almost<br />
esabs e o edo t ejob eg a ost<br />
249,000 tons – this equals the weight of 585 fully<br />
loaded Boeing 747’s
Fun Facts<br />
�� The slabs removed on the<br />
job will reach 8.03 miles<br />
high if stacked on top of<br />
one another th (7000’ above b<br />
most airplane cruising<br />
altitudes)<br />
� This equals covering a<br />
football field to a height of<br />
6 stories<br />
t i
ROTOMILL - 261,000 SY
SUBGRADE PREPARATION - 67,800 SY<br />
Over 10,000 CY of low slump<br />
concrete t was required.<br />
i d
UNDERDRAIN - 74,000 LF OF 6”-8” PERF. PIPE<br />
13,400 LF NON PERF. PIPE<br />
Fun Fact – During the best 24-hour 24 hour<br />
period about 6,000 LF of underdrain<br />
was installed installed.
ASPHALT PAVING - 70,300 TONS<br />
Fun Fact – During the best<br />
24 24-hour hour period over 6,000 tons<br />
of asphalt p was p<br />
placed.
Concrete Paving<br />
Fun Fact – During the best<br />
24 24-hour hour period over 10,000 cy<br />
of concrete was placed or an<br />
average of 416 cy/hr cy/hr.
The Job<br />
Progress g
Day 7
Day 14
Day 27
Day 39
Day 54
Opening Day – Day 59 1/2
Final Fun Facts<br />
We Made It!<br />
� At our peak we did $12.5<br />
million of work in a week.<br />
� Th That t is i the th equivalent i l t of f<br />
doing $650 million / year!<br />
�� At peak peak we worked over<br />
18,000 man-hours.<br />
� That is the equivalent q of 450<br />
people based on a 40 hour<br />
work week or 936,000 man-<br />
hours / year!<br />
� Over the 42 days of concrete<br />
paving p g we averaged g 3,650 , cy y<br />
every day or 160 cy every<br />
hour.
Keys to Success<br />
� Complete Team Effort<br />
� Phasing (Aircraft Movement Simulation)<br />
� Detailed Planning (<strong>Airport</strong> & Contractor)<br />
� Pre-construction Investigation / Test Strips<br />
� Resources<br />
� Quick Issue Resolution<br />
� 24/7 Engineer Support<br />
� Consistent Mix Design g<br />
� Wireless Paving<br />
� Maturity y<br />
Meters
Team Celebration
THANK YOU!<br />
QQuestions? ti ?