Client: AIC Infrastructure Pvt. Ltd.
Location: Mumbai; Maharashtra
Shoot Dates: February & March; 2019
Project Execution: 12 Weeks
AIC Infrastructures Pvt Ltd. is in the business of pavement constructions, repair and restorations with specific focus on aviation infrastructures.
AICIPL has executed various aviation related infrastructure projects, which are completed with consistent quality and safety assurance and adherence to scheduled project timetable. These projects include construction of runways, retaining wall, bridges, advance drainage and various concrete pavement works including construction/ expansion / renovation of taxiways.
AIC are proud to be associated with Airport Infrastructure works with focus on high quality, value for money and infusion of the latest technology from across the globe.
India’s premier airport in Mumbai , the Chattrapati Shivaji Maharaj International Airport is developed, operated, modernized and managed by Mumbai International Airport Ltd., a consortium led by GVK. It is located in the financial capital and a key gateway to the country, playing a crucial role in aiding the city retain its premier position and fast paced growth.
The Mumbai airport is known to be the busiest single runway airport in the world. It integrates world class design, architecture, infrastructure and operational efficiency.
On most days, this airport handles over 1000 aircraft movements and approximately 140 thousand passengers.
This means there are 2 flights taking off or landing every 3 minutes!
No mean feat indeed!
The runway is the heart and soul of any airport – its most valuable asset.
It is imperative that this key asset is always available and safe.
Mumbai airport has two cross runways - 09/27 (the main runway) and 14/32 (the secondary one) which intersect, making only one of two runways operational at a given time.
The amount of traffic entails a lot of wear and tear, and runway maintenance is a 24/7 responsibility.
Runway pavements are exposed to different stress, as compared to other pavements - Like, Air traffic counts Weather exposures, and Oxidization of surfaces.
Over time, the surface gradually begins to weaken, and needs to be resurfaced.
In order to ensure safer operations, it is essential to give it new life, by milling and resurfacing with hot mix asphalt over the existing surface.
The mammoth task to strengthen and re-profile this super-busy airport was entrusted to AIC Infrastructures Private Limited, Mumbai.
AIC is focused on the field of Infrastructure-building, and is specialized in construction and repairs of airfield pavements globally.
It orchestrates projects with consistent quality and safety assurances, with adherence to planned project timelines, all of this infused with the latest machineries and technologies.
The experienced airport team executed this project with the best of quality and safety practices.
The project to revamp and resurface the runways was executed in a precisely planned manner in phases, starting with the intersection, and then working on the other two runways.
Resurfacing of the runway to ensure strengthening and other aeronautical ground light works.
Every day the activity started by taking over of runway at 11.00 am and ended with handing it over at 5.00pm; every Tuesday, Thursday and Saturday, that is, it was completed in just 22 closures, over a period of 7 weeks.
Let us take a look at how this entire Operation was carried out. Every second, every minute of final activity on site was planned to the minutest degree of perfection.
Working closely with MIAL’s Engineering, Airside Operations and Security teams, the engineering team planned the work meticulously to ensure that they hit the designated target start and end dates.
In a record time of one month the asphalt plant was procured, installed and commissioned, at the Mumbai Airport.
The Master Control Room at the Asphalt Plant set up at the Airport premises - everything was precision-planned by the hand-picked team of very experienced, seasoned and skilled engineers, workers and operators.
All the required aggregates from the best of quarries were sourced and transported over 100 kms, from the airport, and stocked.
Specially engineered & formulated bitumen with the required airfield specifications was procured and supplied for the project.
And Fine Hydrated Lime sourcing and supply lines were ready and feeding regular consignments.
The plant site was equipped with a state of the art laboratory, which pre-checked all raw materials before being used. The highly experienced professionals designed the asphalt mix and ensured that the hot mix plant produced the same. Continuous pre and post checks ensured that mix to be laid on the runway was of designed and desired quality.
All the Environmental control procedures were followed and extra measures, unique to our global standards in India, were taken.
A special Water Mist System, comprising Dust Separators and Suppression Sprayers to separate the dust, along with fog cannons, were installed to adhere to environmental norms.
The process of the Production at the Hot Mix Plant was done at this huge automated plant, which integrated the Aggregates from this covered feeding hopper up into the silos right on top. During the process the aggregates were heated in this insulated drum to ensure that the temperature of the mix was achieved.
The fine dust was separated and mixed with water to form a sludge that was transported away. The aggregates were then separated and graded into five different sizes through five channels.
The hot Bitumen was fed up into the hopper via this feeding pipeline, and the lime dust went up here. All the raw ingredients were mixed thoroughly for a predefined period to ensure the mix was homogeneous.
Finally the Hot mix was unloaded into tippers. Tippers were kept covered to ensure that the temperature of the mix was retained for a longer period.
Now for the action!
At 11.00 am, and the last flight has taken off. The ATC tower gives the flag-off to enter the runway and the race against time begins.
There are some quiet preparations on the sidelines too. An On-site Ambulance for any emergencies, a 110 Ton crane, 40 feet trailer, for emergency breakdown of heavy machinery and of course, a mobile toilet unit.
Safety is a priority not an option. We care for every personnel on & off field.
Time is so precious in this window of opportunity, that all measures have been taken to minimize downtime.
A team cores and removes the existing AGL lights fitting followed by filling the void with a quick-set concrete.
Surveying machines determine the existing pavement levels to achieve design standards.
During the first 3 hrs., the 4 high powered milling machines are working at a remarkable speed to mill of over 3500sqm of existing asphalt surface and tons of mill waste is transported away from the runway.
The cleaners - Bobcats and Compressors - follow the milling machine and clean the surface making this a simultaneous sequencing job.
After the cleaning, a layer of bitumen tack coat is applied on the surface by the automatic bitumen sprayer to improve the binding of the new asphalt premix to be laid.
In no time, modern pavers equipped with high compaction screeds and precise automatic levelling system begin laying the asphalt over the milled surface.
This Echelon paving is one of its kind on an operational airport in India.
This was the special airport asphalt pre-mix designed by jointly by MIAL and AIC in order to provide strong wearing course to the runway.
Without delay the 6 tandem vibratory rollers start compaction of the asphalt.
As the desired rolling passes are achieved, the 3 pneumatic tyre rollers join them to give a proper kneading effect to the compacting surface.
The surveyor then performs the final check on the levels while the compaction of the HMA is checked by PQI- Precision Calibrated Pavement quality indicator to ensure the required compaction.
The asphalt temperatures are constantly cross-checked.
Once the quality checks are done, the house keeping team starts the chicken parade to look for possible Foreign Object Debris on the surface.
The AGL lights are fitted back in the runway before the painting commences.
The final marking of the runway is reinstated, before handing over of the runway to the Airside operations team for their final check, well before the 5 pm deadline for the day.
As the signal is given, the entire fleet of machinery and equipment moves away immediately to vacate the runway.
Every single minute counted, and hence every single operation had been pre-timed to be completed in an exactly pre-determined time-frame.
A High Quality solution, with impeccable safety practices, was provided, to this resurfacing project at MIAL, Mumbai, India.
It is a great testament to the professionalism and commitment of every single AIC personnel that they were able to ensure the successful completion of such a crucial and prestigious project. Another feather in AIC Infrastructure’s cap, working in close coordination with CSMIA – MIAL and GVK!
The project was completed within the stipulated time frame of 8 weeks including the 3D animation, voice over recording and editing.
The final video of over 20 minutes was appreciated by all stake holders and we added a yet another feather in our cap!