John Rone, PE

Concrete Pavement Repair &Maintenance at Hartsfield-JacksonAtlanta International AirportJohn Rone, P.E.Aviation EngineerHartsfield-Jackson Atlanta International Airport1

AgendaI. ATL FactsII. Why?III. Pavement MaintenanceIV. Locating and Evaluating DistressesV. Preparing Plans and SpecificationsVI. Repairing DistressesVII.Recording Repairs2

I. ATL Facts• Busiest Airport in the World• Over 930,000 operations per year• Over 90 million passengers per year• 5 Runways – averaging 2,700 daily operations• 21 Taxiways• Over 40 million S.F. of PCC pavement• Approximately $2 Billion3

I. ATL Facts4

Runway Construction & SectionsRunway Year Section Slab Size8L-26R 84-85 16/6/6 25’x50’8R-26L 2006 20/2/6 25’x25’9L-27RCenter 1974 16/6/6 25’x75’E 2,100’ 1985 16/6/6 25’x50’W 1,800’ 1985 16/6/6 25’x50’9R-27L 1999 18/4/6 25’x25’10-28 2006 20/9 25’x25’5

I. ATL Taxiways• Organized For Inspection – 14• Grouped by major parallel• Sierra and Tango with November, 9L-27R, andMike• Constructed between 1964 and 2011• M10, M12• Lima and Mike6

II. Why?• Safety - Aircraft7

II. Why?• Safety - People8

II. Why?• Asset Preservation• Operational Impact• Operations per day• Arrival Runway 1,002• Departure Runway 1,0059

III. Pavement Maintenance• Three Major Categories, Two EntitiesA. Emergency Repairs – DOA MaintenanceB. Major Replacements – DOA P&DC. Annual Repairs – DOA P&D10

A. Emergency Repairs• Methyl Methacrylate• Restek MMA-basedpolymer concrete11

A. Emergency Repairs• Revere Sta-Fil asphalt patch• Replaced with Restek within 10 months12

B. Major Replacements: 5-Year Plan14

C. Annual Repairs• Scope Screening• Safety• Preservation of Assets• Part 139 Compliance15

C. Annual Repairs• Typical Project Scope• Striping and Markings• Grading• Shoulder Rejuvenator (As needed)• PCC Repairs16

C. Annual Repairs PCC Scope• Joint Seal• Crack Routing and Sealing• Spalls• Utility Spalls• Trench Drains• Full Depth Slabs17

IV. Locating & Evaluating DistressesA. Runway and Taxiway InspectionsB. Field Data Collection Techniques18

A. Runway and Taxiway Inspections• Total Inspection Area• Approximately 23 million square feet• Total Nights• 16-18• Average Area Per Night• 1,350,000 square feet• Distances Covered• Typically Between 5 and 8 miles19

B. Field Data Collection Techniques• Typical Night• Arrive 9:00 - 10:00• Check survey equipment• Check weather• Confirm with Maintenance and Airside Operations• Go to field• Meet light plants• Inspect• Return to Tech Campus20

Our Equipment• RTK System• Paint Wand• Dowel Bar• Flashlights• Radios• Juno21

Maintenance Equipment• Trucks (2)• Light Plants (2)• Alert Drivers22

Pavement Inspections• Runway Closures 2330-0630• Closed to hold bars – 290 feet• Mainline then connectors• Easiest way to organize• No backtracking• Taxiway Closures - Unit 5 Dependent• Some: Rolling closures between connectors• Others: Open – “You should be o.k.”• 747 in the dark• Mainline then connectors23

Pavement Inspections• Monitoring Radios• Especially for active pavements• City for Unit 5• South Cargo – R6 and KAL• Tower for Aircraft• Crossings• Location of aircraft24

Arrival at Distress• Spalls, Utility Spalls, and Trench Drains• Sound with dowel bar to finddelaminated area• Mark perimeter• Evaluate severity• High• Medium• Low25

Arrival at Distress• Survey with GPS unit• Start at SW corner, shootCCW• Differing codes• Changes description field• Paint number onpavement• Photograph• From SW corner26

Arrival at Distress• Joint Seal, Crack Seal, and Full Depth Slabs• Mark vertices• Survey with GPS unit27

Distress Field Evaluation• Spall Distress Types• High Severity• Medium Severity• Low Severity• Watch• Typically an existing patch• May sound slightly hollow• Modify by Location – Engineering Judgment• Age• Traffic28

Evaluation - High Severity Spall• Must be addressed this year• Active FOD Producers• High Traffic Locations29

Evaluation - Medium Severity Spall• Should be addressed this year• FOD potential• Lower traffic30

Evaluation – Low Severity Spall• Will not appreciably deterioratewithin a year• Repairs by Maintenance• Existing hollow patches• Low FOD potential31

Evaluation - Utility Spalls• Utility Spalls• Conduits cut intopavement32

Evaluation – Joint Seal• Missing• Damaged/Not Adhering33

Evaluation – Crack Sealing• Judgment34

Evaluation - Trench Drains• Sound of wall• No energy return35

Evaluation – Full Depth Slabs• Pavement Evaluation Report• When spall repairs are not enough36

Distresses – Potential Causes• Improper Dowel Bar Alignment - Spalls37

Distresses – Potential Causes• Consolidation• Age/Loads• How do you make PCClast?• Location of Reinforcing• No steel?• Too Deep?38

Distresses – Potential Causes• Materials39

Distresses – Potential Causes• Own Worst Enemy40

Field Work Completion• Download survey data• Save photos• Equipment on chargers• E-mail Airside Ops for next day’s closure• Update AutoCAD basemap with area inspected• Update actuals spreadsheet with area and timerequired• Forecast time required for next area• Target 1,000,000 S.F. min.41

V. Preparing Plans and Specifications• AutoCAD Base Drawing• Import field data• Connect points• Photos are critical• Offset limits at joints• 6” offset• Measure quantities• In drawing• Tracking• Quantities• Spall master list• Can zoom to anypoint• Ops• Distress Drawings42

Construction Details43

Construction Details• Utility Spall44

Closure Plan Requirements• Closure times• Full Slabs: 2200 – 0800• Trench Drains: 24-hours until completion• Other Repairs: 2330 - 063045

Specification Requirements• Spalls – High Early• Materials• High-early strengthcement – Approx. 900lbs.• Polymer fibers• #7 or #89 stone• Flexural Strength• 400 psi at 4 hours• 700 psi at 24 hours• 4 hours of cure timerequired• Slab Replacements• Materials• High-early strengthcement• Flexural Strength• 500 psi at 4 hours• 750 psi at 28 days• Trench Drains• Materials• Type III cement• #7 stone for amount ofrebar• CompressiveStrength• 2,500 psi at 3 days• 3,000 psi to open46

VI. Repairing Distresses• Joint Seal• Crack Seal• Spalls, Utility Spalls, Slab Replacements47

Joint Seal Repair• Remove sealant• Saw cut, rebevel• Sandblast• Air wand• Insert backer rod• Install sealant• Width• 25- and 50-foot slabs:3/8”• 75-foot slabs: 1/2”• Expansion: 1-1/2”• Trench DrainExpansion: 3”• Set down• Taxiways and Aprons:3/8”• Runways:1/2”48

Crack Seal Repair• Rout to 3/8” width and 3/8” depth• Sandblast• Air wand• Insert backer rod• Install sealant49

Spall Repair• Typical Spall Repair Sequence• Pre-sawing• Mass demolition• Fine demolition• Debris removal• Bobcat• Brooms• Air wand• Sandblasting50

Spall Repair• Typical Spall RepairSequence, Cont.• Drill rebar holes• Epoxy• Place reinforcingsteel• Set expansionmaterial• Clean• Grout• Place concrete• Consolidate• Finish• Cure51

Pop Quiz1. Is this a distress?52

Pop Quiz2. Is this dowel bar installed at the properdepth?53

Pop Quiz3. Is something missing?54

Pop Quiz4. Does this joint meet spec?55

Pop Quiz5. If there’s white paint covering the box atHome Depot, should you buy it?56

Spall Repair: Tango at 9L-27R• Sample Spall Repair Location• Between 9L-27R and November on Tango• Spall 5634, Northern• Spall 5641, Southern• Areas• Spall 5634 – 29 S.F.• Spall 5641 – 23 S.F.• Total time• 2350 – 0301• 3 hours, 11 minutes57

2350 at ATL58

2350 E.T. 00:00• Lighted Xs placed• Vehicles enter runway59

0004 Demolition E.T. 00:14• After barricade placement at 2352• Demolition begins60

0015 Mass Demolition E.T. 00:25• Initial debris clearing61

0015 – 0040 Concurrent Activities• Concurrent with demolition, other areas arepre-sawed62

0015 – 0040 Concurrent Activities• To prevent overcuts, corners are cored63

0015 -0040 Concurrent Activities• Reinforcing steel being prepared64

0015 -0040 Concurrent Activities• Bulk of debris is swept up and removed65

0040 Fine Demolition E.T. 00:50• Chipping hammer used to smooth bottom66

0040 E.T. 00:50• Saw used to cut existing patch bars67

0051 Air Wand E.T. 01:01• High pressure air used to remove debris68

0105 Sandblasting E.T. 01:15• Sandblasting spall 5634 to roughen surfaces• Air wand after69

0115 Sandblasting E.T. 01:25• Sandblast spall 564170

0115-0135• Pavement distress for next night71

0115-0135 Drilling• Drilling for rebar in spall 563472

0145 Epoxy E.T. 01:55• Inject Epoxy for Reinforcing Steel73

0205 Expansion Material E.T. 2:15• Expansion Board Placed75

0219 Ready for Final Cleanup E.T. 2:29• Spall 5634 Reinforcing Complete76

0219 Air Blasting E.T. 2:29• Air Blast Spall 563477

0225 Concrete Placement E.T. 2:35• Zimmerman Volumetric Mixer Backed intoPlace78

0227 Concrete Placement E.T. 2:37• Water Sprayed into Spall 564179

0231 Concrete Placement E.T. 2:41• Material Tested into Bobcat• Grout Applied80

0236 Concrete Placement E.T. 2:46• Spall 5641 concrete placed and consolidated81

0237 Concrete Placement E.T. 2:47• Concrete Placement Completed at Spall 564182

0239 Finishing E.T. 2:49• Strike-off and Finishing at Spall 564183

0240 Concurrent Activities E.T. 2:50• Beams being Made84

0244 Concrete Placement E.T. 2:54• Concrete Placement at Spall 563485

0251 Concurrent Activities E.T. 3:01• Beams Covered with Wet Burlap86

0252 Finishing E.T. 3:02• Finishing Complete at Spall 564187

0252 Concurrent Activities E.T. 03:02• More Sweeping88

0254 Finishing E.T. 3:04• Finishing Continues at Spall 563489

0254 E.T. 3:04• Wet Burlap on Spall 564190

0301 E.T. 3:11• Finishing Complete on Spall 563491

0301 E.T. 3:11• Wet Burlap on Spall 563492

VII. Recording Repairs93

QuestionsJohn Rone, P.E.Aviation EngineerHartsfield-Jackson Atlanta InternationalAirport94