This document provides information about airport runway construction including: - The typical components and layout of an airport including runways, taxiways, terminals, and control towers. - Factors that influence runway orientation such as wind patterns and obstructions. - The purpose and types of runway markings, signs, and lighting. - The sequence and methods for constructing a runway including earthworks, aggregate base course, asphalt paving, and markings. - The types of equipment used such as excavators, loaders, pavers, rollers, and sprayers.

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IIT Delhi
Department of Civil Engineering
Airport Runway Construction
Prepared by:- Abdul Habib
Subject: Construction Equipment & Method
Instructor: Pro. A K Jain

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TABLE OF CONTENTS
 Introduction
 Objectives
 Construction processes of Airport
Runway
 Airport
 Airport History
 Typical Layout of an Airport
 Components of Airport
 Airport Runway
 Runway Configuration
 Runway Orientation
 Factors Affecting Runway Orientation
 Runway Markings
 Runway signs
 Runway Numbering
 Runway Numbers
 Runway Lighting
 Equipment Which Will be used in Airport
Runway Construction
1. Trench Excavation
2. Backfilling Equipment
3. Soil Transport Equipment (Load Tipper Truck)
4. Grader Equipment used for the Grading of soil
5. Dozer Pushing Clay
6. Hydraulic Rock breaker
7. Asphalt paving
8. Bitumen Emulsion Sprayer Equipment
 Runway pavement
 Runway Cleaning
 Runway Tests
 Repair of Airport Runway
 References

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INTRODUCTION
Airport engineering is the planning, design, construction, and
operation and maintenance of facilities providing for the landing and
takeoff, loading and unloading servicing, maintenance, and storage of
aircraft.
This Engineering encompasses the planning, design, and construction
of terminals, runways, and navigation aids to provide for passenger
and freight service.
An airport is a facility where people connect from ground
transportation to air transportation
In the airport, runway is an area where an aircraft can land and take
off, which may or may not be equipped with any navigational aids or
markings

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Objectives
The purpose of this presentation is to give an understanding of the Methods,
Plant and Sequence to construct a Runway which will be shown in the next
slide.
This presentation can be used to engage Stakeholders and to get the Site
Teams commitment to the program. Also can be used for Induction Training
and as a way to capture and share knowledge.

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Construction processes of Airport Runway
Runway Construction
Sequence & Methods
Earthworks
Crushed Aggregate Base Course
Asphalt Paving
Pavement Marking
Cleaning Pavement
Airfield Ground Lights
Glide Path & DVOR
Electrical Substation
Taxi Guidance Signs
Concrete Paving
Milling/Planning Machine
Cable Laying
Directional Drilling
Fencing
Operational Restrictions
Article on Runway Pavement
Pavement Details & Mixes
Concrete, Rebar & Shuttering
Concrete Wall Construction
Culvert & Head Walls
Oil Interceptor
Pump Station
Concrete Mix Design
Compacting Concrete
Safety & Environmental
Emergency Numbers & Response
Dashboard for Monitoring & Reporting HSE
Safety Generally
Personal Protective Equipment
Excavation Safety
Trench Safety
Training
Emergency Response Drill
Safety documents
Environmental Measures
Hazardous Substances Symbols
Water Pollution Prevention
Segregation of Waste
Using Waste Concrete
Contractor Site Facilities
Methods
Checks
Airside Restrictions
Stakeholders Engagement
Contractor Site Facilities
Offices, Stores and etc.
Welfare facilities
Hoarding
Fencing
Dewatering
Wheel Wash
Electricity & Lighting
Asphalt Batching Plant
Concrete Batching Plant
Crushed Aggregating Batching
Quarry & Aggregate Production
Reinforcement Cutting & Bending
Administration
Organogram
Staff Responsibilities Matrix
Staff Directory
Daily Work Record
Quotation Comparison Sheet
Digital Filling System
Quality Assurance
Dashboard For Monitoring &
Reporting QA / QC
Tests
Site Laboratory
Program & Progress
Monitoring
Reporting Progress
Histograms
Resources – Plant & Manpower List
Programs
Miscellaneous
Terminal Building
Air Traffic Control Tower

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Airport
 A place from which aircraft operate that usually has paved runways
and maintenance facilities and often serves as a terminal.
 A place where aircraft regularly take off and land, passengers.
 An airport is a location where aircraft such as fixed-wing aircraft,
helicopters, and blimps take off and land.
 An airport consists of at least one surface such as runway for a plane
to take off and land, a helipad, or water for takeoff and landings, and
often includes buildings such as control towers, hangers and terminal
buildings.

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Airport History
 The world’s first airport was built in 1928 at Croydon near London
(England).
 It was the main airport for London till it was closed down in 1959,
after the World War 2.
 It is now open as a visitor center for aviation.

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Typical Layout of an Airport

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Components of Airport
An airport has two major components;
1. Airfield
 Runway: used for takeoffs and landings.
 Taxiway
2. Buildings
 Terminal buildings
 Control towers
 Helipads
 Apron
 Aircraft stand
 Parking

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Airport Runway
Runway is a paved land strip on which landing and
takeoff operations of aircrafts takes place. It can be
grass, or packed dirt, or a hard surface such as asphalt
or concrete.
Special markings are made on the runway to differ it
from the normal roadways. Similarly, after sunset,
specially provided lightings are helped the aircrafts
for safe landing.
Runway can be laid using bitumen or concrete.

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Cont…

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RUNWAY CONFIGURATION
According to Federal Aviation Administration (FAA) there are
four common types of runway
Single runway
Parallel runway
Two parallel runways
Two parallel runways with staggered thresholds
Four parallel runways
Open-v runways
Intersecting runways

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Cont…
 Runway configuration depends on CAPACITY.

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Runway Orientation
Runway orientation is important in airport planning
Current practice is to layout a runway in the direction of
prevailing wind
It is very important for safe take offs and approaches
The width and sloping of runway also play a role in safe
approaches

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Factors Affecting Runway Orientation
WIND
Airspace availability
Environmental factors
Obstructions to navigation
Air traffic control visibility
Wind lift hazards
Terrain and consideration

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Runway Markings
These are provided with different purposes like
1. Runway centerline marking
2. Runway edge stripe
3. Runway numbering
4. Touch down or landing zone marking
5. Threshold marking
 Defines specific height by which aircraft should cross it
6. Two or more parallel runways

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Cont…
Runway Centerline Marking
1. It is represented by a broken strip running along the entire
length of runway
2. Length of strip should be equal to length of gap or 30m
whichever is higher.
3. Length of strip plus gap shall not be less than 50m and
more than 75m
4. The width of strip shall not be less than 90cm on precision
approach runway and 30cm to 45cm on non-precision
approach runway.

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Cont…
1. Blast pad: The area marked with yellow chevrons (V
shaped) also referred to overrun areas or stop ways.
• Constructed to reduce the erosion of earth by the jet blast
produced during power up to take off

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Cont…
Run way Threshold Markings: it consists of pattern of
longitudinal stripes of uniform dimensions placed symmetrically
about the centerline of a runway.
Touch down zone: it is the target area for pilots to stick the wheels
of aircraft on to the runway

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RUNWAY SIGNS
These runway signs are used for various purposes.

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RUNWAY NUMBERING
The end of runway is marked with a number that indicates magnetic
azimuth.
East end of East-West runway will be marked 27 (for 270 degree)
and the west end is marked 9 for 90 degree.
Every runway is numbered between 01 and 36 at each end of runway.
Angle between the direction of the centerline of the runway and the
magnetic north.
Or simply, 360° means north, 90° means east, 180° means south and
270° means west
For more than one runway going in the same direction, letters are
added to the end of the number R for right, C for center, and L for
left.

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Cont…
A runway 16/34 would be (160°=16) pronounced as one six.
The number at the other end of the runway is the opposite
number on the compass and that would be (340° = 34)
pronounced three four.
The difference between 340° and 160° is 180° or put another
way, 34 minus 16 equals 18.

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RUNWAY NUMBERS

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Runway Lighting
These lights are used to assist pilot in to identify the
runway
GREEN THRESHOLD LIGHTS: Line the runway
edge
RED LIGHTS : Mark the end of runway
BLUE LIGHTS : Run alongside taxiways
While runways have YELLOW or WHITE lights
marking their edges

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Cont…

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Runway Construction and
Construction Equipment Working
on an Airport Runway

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Runway Construction Sequence & Methods

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Runway Construction Pavement Details & Mixes

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Cont…
 Runway Asphalt.

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Cont…
 Runway Ends Concrete
• APC (Asphalt pavement
concrete)
• HDPE (High Density
Polyethylene)
• CSBC(crushed surfacing
base course)
• SBC(surfacing base
course)

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Earth works
Subgrade preparation
1. Soil investigation
2. Survey and setting out works
3. Excavation and filling
4. Grading
5. Compaction
Excavation of soil as per required level with an excavator
Damping of excavated soil by dumpers at suitable places
Grading of excavated area
Compaction by rolling

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Equipment Which Will be
Used in Airport Runway
Construction

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Cont…
 Trench Excavation

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Cont…
 Backfilling Equipment

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Cont…
 Soil Transport Equipment (Load Tipper Truck)

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Cont…
 Grader Equipment used for the Grading of soil
o Subgrade is to be prepared in layers
o After dumping of soil, dozing is to be done with a dozer
o Grading is to be done with a grader as per the required
slopes and gradients

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Cont…
o Spreading and compaction clay fill
o Dozer Pushing Clay

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Cont…
o Dozer Ripping Ground

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Cont…
o Excavator with Hydraulic Rock breaker
Earthworks

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Cont…
Compaction
o After grading, rolling is to be done with a roller of 8-10 tons
capacity
o Rolling should be done at OMC(optimize moisture content) of the
soil
o There should be at least 6 passes (1 plain+2 low vibration +2 high
vibration +1 plain pass)
o Rolling should be started from outer edge of the pavement and
should proceed towards center
o There should be 1/3 overlap in the previous pass
o The compaction should be at least 98%

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Cont…
o CABC (Crushed aggregate base course ): CABC is produced by
the accurate proportioning and blending of four agg. Sizes and
water using agg. Stabilizer batching plant, after verification that the
sub base layer is within the specified tolerances the surveyors
establish string lines with support pins at 10m centers.
o The mixed agg. Base course is delivered by tipper trucks to the job
site and tipped into the pavers hopper.
o Generally 6 to 7 trucks are required, the material is applied in
layers not exceeding 150mm compacted thickness
o The agg. Base course is spread using tracked pavers fitted with
automatic screed control to the required width, thickness, profile,
camber and cross fall.

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Cont…
For Crushed aggregate used for base course a crush plant is
required

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Cont…
Spreading & Compaction CABC ( Crushed aggregate base course )

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Asphalt paving
Asphalt pavers: The asphalt paver is a self-propelled
formless laydown machine with a floating screed.

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Cont…
Prime Coat Site Trials: prior to starting paving all the
materials are pre-tested in and a site trial is curried out to
familiarize the crew with the equipment and characteristics
of the particular asphalt mix and to ensure that the
workmanship as will as the material complies with the
specification requirements.
The polymer modified bitumen asphalt mix is laid with two
trucks paver equipped with extending screed tamper and
vibrator and conveyer.

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Bitumen Emulsion Sprayer Equipment
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.

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Cont…
Paving methodology
o Prior to paving, the GSB surface should be cleaned of roots, grass,
stones etc.
o GSB surface should be made slightly moist and should be rolled
for 2 passes
o After the paver has been positioned properly, paving should be
started
o Rolling should be done completely prior to setting of concrete.
The pattern of rolling should be same as that of subgrade

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Cont…
o The pavers operate using an automatic screed control which
controls the screed height using the string line or the
matching shoe as a level reference.
o The un-compacted asphalt level behind the paver is checked
by pulling a sting lone between the longitudinal string lines
at the 10m pin location and taking dip measurements using a
tape measure.

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Cont…
o Level control is maintained by two string lines as a great
reference system for the lead paver and matching shoe and
one string line for the following paver.

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Cont…
Runway Asphalt Pavement Line and Level
o String line used for level and line reference

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Cont…
o Runway Asphalt Pavement

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Cont…
R A P -4 Pavers working together

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Cont…
o The asphalt after compaction reduces in thickness by
approximately 20% dot the jointing and laying the
sequence across the runway is design to insure that the
longitudinal joints are staggered by 300mm between
layers.
o Free edges that will form joints are cut back by 100mm,
the level tolerance is +6mm and the smoothness
tolerance is a max 6mm with a 3m long straight edge.

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Cont…
o Cutting Joint

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Cont…
o Average output is 4 to 5 loads per hour, that is equal to
120tons/hour.

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Runway pavement
 Marking
o Pavement marking to runway using an emulsion paint.

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Runway Cleaning
Cleaning surface with rotating water jets
o High pressure spinning water jets are used to remove rubber
from runways that builds up as result of planes landing.

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Runway Tests
Test for Skid Resistance
o Using the Douglas Mu-Meter Continues friction
measuring equipment

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Cont…
Test for smoothness using Rolling Straight Edge

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Repair of Airport Runway
After the construction of airport runway, and other structures
(Buildings, Towers, and etc.) regular maintenance is required
for the service life those structures. And the following
recommendations have to be followed.
1. Airport structures must be safe as much as possible from
deteriorations (cracks, deterioration of clear cover and
etc.)
2. Cracks maintenance has to done regularly.
3. After seeing a deteriorated place the maintenance has to
be done on time.

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Thank you

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References
• Airport Planning and Design
• Runway Contraction Project
• Field Guide for the Airport Pavement Maintenance
Recommendation tool for ACRP Report 159
• Fast and Permanent repair for airport structures
• Google Images
• https://www.scopus.com