How It's Done – Paving a Runway Video

So, I thought it would be cool to shoot a video on  how they paved the runway, and turns out, I was right – it is cool.  Maybe I’m a nerd, but I found it amazing how they brought in the concrete material, then formed it into a beautiful, nearly flawless, 15 inch slab, working many yards in mere minutes.

The dump trucks would pull under a huge loader that would fill its bed with 10 yards of concrete in 2 minutes.  With the time it takes for the truck to stage its position, load and move for the next truck, a truck can be filled every 2.5 minutes.
Paving the Runway at the new Panama City Airport from Jason Koertge on Vimeo.

The runway paving process was, I thought, interesting. Consisting of 15 inches of concrete on top of 4 inches of asphalt, the runway will be capable of handling the load of the largest of aircraft.

Each dump truck would back the loads down the asphalt sometimes up to a quarter mile, then dump their load right in front of the first machine.  As the machine worked the pile of concrete to fit under its 15 inch clearance, workers would grab a sample of the concrete with shovels to take back and test.  Each load of concrete was tested to be sure that it met the proper strength requirements.

As the concrete passes under the machine, 1 inch rods comb through the mixture vibrating at a high rate of speed to be sure the mixture compacts.  It exits the other side a basic form, but not smoothed.  The next machine refines the shape, vibrates and compacts more and spits the smoothed almost finished runway out the back end.

The main 8,600 feet of the runway is paved as of right now and upon arrival of the FAA approval of the extension, the remaining 1.400 feet will be paved in about 10 days.

Airport Construction Update – Terminal 18% Complete

Contract 1: Heavy Civil and Airfield Lighting
Approximately 80% of the contract work is complete with only 54% of the contract time used.

  • 90% of the 15” concrete paving lanes have been placed on 8,400 linear feet of Runway 16-34.
  • On Taxiway D and main terminal apron, all lime rock base and the first lift of asphalt paving is in place with the 2nd of four lifts going down this week.
  • The centerline cans on the runway are approximately 36% complete.
  • The lighting cans in the Touch-down zone are approximately 55% complete.
  • Paving will begin this week on the General Aviation Access road.
  • 150 pieces of heavy equipment are in operation at any one time with approximately 200 personnel on site for the heavy civil and utilities contracts.

Contract 2:  Terminal Building, ATCT and Support Buildings
Approximately 18% of contract work is complete with 22.6% of contract time utilized.

Concrete pouring complete for Level 2 Area A. Shoring of Level 2 Areas B and C continues

Air Traffic Control Tower:
Cutting of auger cast piles to design length is complete. Forming for the pile cap has started.

Air Maintenance Facility:
Forming for pit walls continues.

Air Cargo Facility:
Continuing the installation of the pre-engineered metal building.

Public Safety Building:
Rough-in of the plumbing continues.

Rental Car Facility:
Installation of underground facilities continues.

The average man power on site for Contract 2 per day is 95 people based on a five day work week.

Contract 3:  Utility Contract
Approximately 8% of contract work is complete with 11% of contract time utilized.

Main Access Road:
3W2” Power Distribution Duct Bank is 36% complete.
Street light duct work is 50% complete.

Joyner Road:
24” directional bore is complete.
24” water main is 36% complete.

GA Access Road:
30” water main is 9% complete.

Lift Station:
Wet Well is installed.


New Airport Constructin Update

Construction at the new Panama City-Bay County International Airport continues to run smoothly and is currently about 3 and a half months ahead of schedule.  A summary of the contracts underway follows.

  • Contract 1: Heavy Civil and Airfield Lighting:
  • 115 pieces of heavy equipment in operation at any one time with approximately 160 personnel on site.
  • 46% of time utilized (360 of 780 days).
  • 37% of the 15” concrete paving lanes have been placed on 8,500 linear feet of Runway 16-34.
  • On Taxiway D, all lime rock base and the majority of the first 2” lift of P-401 base have been placed.
  • 12,902 tons of asphalt base course is in place along the Main Access Road (MRA) and loop road.  Curb and lime rock base installation within terminal parking lots now 100% complete.  Asphalt base course is in place over 75% of main parking lot.
  • 34,888 tons of asphalt base and 20,000 cubic yards of structural concrete have been placed on 8,400 linear feet of Runway 16-34.
  • 6,780 tons of asphalt base has been placed on Taxiway D, and the main apron.
  • Stormwater drainage pipe installation is now 99% complete.
  • Storm sewer installation within the General Aviation Area is now underway.
  • Over 5.4 million cubic yards of earth has been moved (98% of total).
  • Mass grading within Pond C now 90% complete.
  • Contract 2:  Terminal Building, ATCT and Support Buildings:
  • Gulf Power has completed installation of temporary overhead power to the Terminal Building location and site office trailers.
  • Installation of reinforcing steel continues along Area’s A and B of the Terminal Building.
  • New design of the Air Traffic Control Tower auger cast piles was required due to the original design not meeting the required load test. The original design required 72 piles drilled to a depth of 52 feet. The new design, based on the actual field load tests will require 44 piles drilled to a depth of 70.33 feet and 28 piles drilled to a depth of 80.33 feet.
  • Rough-in of electrical and plumbing for the Air Cargo Facility is completed.
  • Installation of mat reinforcing steel and dowels for the Air Cargo Facility is completed.
  • Installation of the drainage structures for the Airport Maintenance Facility continues.
  • Contract 3:  Utility Contract:
    • Contract has been executed and all necessary submittals, insurance and bonds have been received from the Contractor. Notice to Proceed is anticipated within the first week of January.