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DESIGN-BUILD FOR AIRFIELD PROJECTS:

Origins, Requirements, and Results

9 July 2015

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Matthew W. Kundrot , P .E . Director – Mil itary Design Group, Delta Airport Consultants

Program Expertise (30 years) Mission Operations Coordination (USAF, retired, 4,000 Hour Pi lot) Project Design and Construction Phasing

Education B.S. Civi l Engineering – Penn State M.S. Aviation Management – Embry Riddle

David A. Burgess , P .E . , L t . Col . ( re t ) Electrical & NavAid Design, Burgess Engineering

Program Expertise (26 years) Airfield Electrical Design, USAF Civi l Engineer Infrastructure Assessment Education B.S. Electrical Engineering – Virginia Tech M.Eng. Construction Management – University of Maryland

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Mil i tary Ai r f ie ld Project/Design-Bui ld Exper ience

P ro jects : Edwards AFB, CA (DB) Andrews AFB, MD (DB) – 4

NAS Jacksonvi l le, FL Columbus AFB, MS (DB)

NAS Oceana, VA (DB) Dover AFB, DE

NAS Patuxent R iver, MD Kandahar AB, Afghanistan (DB)

NS Guantanamo Bay (DB) Lackland AFB, TX (DB)-2

OLF Whitehouse, FL (DB) Langley AFB, VA

Misawa AB, Japan (DB) Forney AAF, MO (DB)

Moody AFB, GA (DB) Westover ARB, MA (DB)

NAS Corpus Chr i st i NAS Pensacola

NAS Kingsv i l le NAS Mer idian

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Out l ine

1. Origin & Requirements of Airf ield Design-Bui ld Projects

2. Why is Design Sti l l Important

3. Special ized Design and Construction for the Airf ield

Environment

a. Civi l

b. Electr ical

4. The Consequences of Improper Scoping

5. Summary and Recommendations

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Or ig in & Requ i rements o f A i r f ie ld Des ign-Bu i ld P ro jects

1. Better, Faster, Cheaper

2. 2001 – The first “GWOT”

3. Contracting Trends and Challenges – One Contract to

Execute Project

4. Special ized Design Required for the Airf ield Environment

- Averting Hazardous Infrastructure Design: Airf ield

Pavements, Obstructions, Electr ical/Lighting/NAVAIDs

- Phasing Requirements Place Restr ictions on Contractor

Production and Increase Construction but Reduce

Operational Costs

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Specialized Design The airf ield environment has design and construction requirements and constraints which are not readily apparent. Consequence of failure is signif icant and potentially catastrophic

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Ai r f ie ld S ignage and

Marking Related Catastrophe

Tenerife, Canary Islands

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Lost Commercial Aircraft Mishaps

Tenerife, Canary Islands –1977 Madrid – 1983

Detroit, MI – 1990 Taipei (Construction) - 2000

Milan – 2001 Lexington, KY (Construction) – 2006

Johannesburg --2013

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Runway Obstruct ion Related Mishap

F-16 Aborted Takeoff

1998 Misawa Air Base, Japan

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Runway Area Obstacles

Remain

Duke Field, Egl in AFB, FL

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Specialized Airfield Civil Design

- Beyond the Footpr int of the Pavement Box - Imaginary Sur faces are Real

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Design Const raints Imposed by Imaginary Sur faces

-Ai rspace

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Design Const raints Imposed by Imaginary Sur faces

Lateral Clearance Areas

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Design Const raints Imposed by Imaginary Sur faces

Longi tudinal P rof i le and L ine of S ight

Tw

y C

harl

ie

Tw

y Si

erra

Rwy 01L/19R 9300 x 200 Primary Instrument Runway

Rwy 01R/19L 9755 x 150

Twy Whiskey

Twy W-4 Twy W-1

Twy Whiskey

Twy Echo

Twy Echo

Twy E-1 Twy E-2 Twy E-3

Twy E-4

Twy A-2

Tw

y W

-2

Pad 92

Pad 93

Pad 94

Pad 12

Pad 13

Pad 14

NAVAIDs Rd

3 4 5

6-7

8

9

18

10 11

12 13 14

Twy E-5 Twy E-6 Twy E-7

16

AM

Tower

ASR VORTAC

LEGEND

N

19 L

01

R

01

L 19

R

1 2 Note: Reference Only; not to scale.

VFR Hold Line

Instrument Hold Line

Glide Slope Critical Area

Localizer Critical Area

Precision Obstacle Free (POFZ) Zone

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Consequences o f not Unders tanding A i r f ie ld Cons t ruct ion f rom an Operat ions Perspect ive

I raq - 2004

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Ai r f ie ld L ight ing System Components

Runway & Tax iway L ight ing A i r f ie ld Guidance S igns Approach L ight ing Systems A i r f ie ld L ight ing Contro l and Moni tor ing System Constant Current Regulators (power d i s t r ibut ion)

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Runway & Taxiway L ight ing

Runway Edge Lights

Runway Centerline Lights

Taxiway Edge Lights

Taxiway Centerline Lights

Touchdown Zone Lights

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Ai r f ie ld Guidance Signs

Runway Hold Signs

Taxiway Guidance Signs

Distance Remaining Signs

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Approach L ight ing Systems

ALSF - 2

ALSF - 1

MALSR

REIL

PAPI

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Ai r f ie ld L ight ing Control Systems

Lighting intensity settings

Operational segregation

Circuit monitoring

Energy usage recording

Diagnostics

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Constant Current Regulators (Power Dis t r ibut ion)

Stand-alone Format

Any size airfield

Easy to relocate

Simple control contacts

Lower initial cost

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Constant Current Regulators (Power Dis t r ibut ion)

Switch-gear Format

Larger airfields

Less time to install

Integrated control

Higher initial cost

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L ight ing Str ing Conf igurat ions

Paral le l L ight ing Ci rcui t Ser ies L ight ing Ci rcui t

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L ight ing Circui t Ground Faul ts

S ingle Faul t Mul t ip le Faul ts

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What are the root causes of improper ly scoped Ai r f ie ld E lectr ical System projects?

1) Lack of ai r f ield electr ical des ign expert i se & exper ience

2) Fai l ing to coordinate ai r f ield l ight ing and paving projects

3) Understanding that ‘meet ing standards’ can st i l l result in a

poor ly des igned ai r f ield l ight ing systems

4) Fai lure to proper ly cons ider the inputs of ai r f ield operat ions and ai r f ield maintenance staff

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Expert ise & Experience

1 Ai r f ie ld l ight ing i s h ighly regulated area of des ign

2 Close interrelat ionship of c iv i l and electr ical des ign

3 Cost of mistakes i s very high in dol lars, operat ional impact and

project v i s ibi l i ty

4 Des ign problems may not be apparent unt i l months or years after

substant ial complet ion

5 Fast pace of technology change and regulatory impact requires

fami l iar i ty wi th industry

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Coordinated Pavement and Light ing Design

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Minimum Standards Misses Opportuni t ies

DESIGN DIRECTIVE Save on construction cost by us ing exist ing handhole/manhole duct bank system

DESIGN DIRECTIVE Save on t rouble shoot ing costs by implement ing a pul lcan plaza based duct bank system

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F ie ld Example – Neglect ing Input f rom O&M Staf f

O&M Design Vacuum

Operational impact

2 wire sizes required

Improper equipment placement

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Design f rom a Systems Perspect ive for Energy Savings

1. LED air f ield l ight ing f ixtures (Savings: over 50% energy reduct ion)

2. Properly s ized Constant Current Regulators (Savings: 10% - 20% energy reduct ion)

3. Air f ield operations based l ight ing control system (Savings: 10% - 30% energy reduct ion)

4. Duct bank system designed f rom an O&M perspective (Savings: reduced “col lateral damage” by reducing maintenance and operat ional impact)

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Edwards AFB, CA Runway 4-22 Reconstruction Design-Build

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Andrews AFB, MD Apron 6B Reconstruction Design-Build

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Andrews AFB, MD: Apron Rehabi l i tat ion

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Randolph AFB: Taxiway G Reconstruction, Design-Build

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Consequences of Improper DB Project Scoping

1. Engineer Works for the Contractor 2. Short Term Repairs 3. Increased Costs

- Project and Infrastructure - Operational Impacts

4. Shorter Infrastructure Life

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Repair-Reconstruct Runway and Taxiway Pavement without Shoulder and Lighting Replacement

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Results: 4 Different Pavement Surfaces and Ages

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Taxiway W Shoulder Pavement - 2000

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“Repaired” Shoulder Pavement – 2014

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Summary and Recommendations

1. Airfield Design-Bui ld project execution is l ikely to remain a contracting option and reality

2. Most common element in fai led project execution is improper scoping.

3. Be prepared with and Airfield Master Plan in order to assess, quanti fy, and prioritize improvement projects

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Develop an Air f ie ld Master/Act ion Plan

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Develop an Air f ie ld Master/Act ion Plan

Andrews

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Summary and Recommendations

4. Plan and Scope Projects from an Asset Management Plan Perspective

- Operations Priority, Systems and Maintenance Perspective

- Airfield Activity Manager is Key. Must be empowered and involved in project planning and coordination.

- AFPD 32-10 Activity Management Plans

5. DB Project Team Must be Airfield Qualif ied and Experienced

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DB Project Team Member Qual i f icat ions

Air f ield Design-Build Projects requires the fol lowing team members:

Owner: Must have a Project Manager with a technical understanding of airfield design criteria and who will solicit input from operations and maintenance staff Design Engineer: Must have specific project experience in airfield electrical & paving design Electrical Contractor: Must have specific project experience in airfield electrical construction Pavement Contractor: Must have specific project experience in airfield pavement construction Use UFC 3-260-11FA “Model Design-Build (D-B) Request for Proposal for Airfield Contracts”. Good information on formulating projects

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Mat thew W. Kundrot , P .E .

Mi l i ta ry Des ign Group, De l ta A i rpor t Consu l tants , Inc .

www.del taa i rpor t .com

804-275-8301

Dav id A. Burgess , P .E . , L t . Co l . ( re t )

Burgess Eng ineer ing, PLLC

www.daburgess .com

571-283-4137