AAA National Airport Industry Awards 2014 BECA Pty Ltd

AAA National Airport Industry Awards 2014

Melbourne AirportSubmitted by Beca Pty Ltd

Corporate Project of the Year:

Foxtrot Apron Infill

The Project

Nominated Corporate Member:

Beca Pty Ltd

Nominated project:

Foxtrot Apron Infill

Airport Project Location:

Melbourne Airport

Date Project Commenced:

September 2011

Date Project Completed:

November 2013

Beca Australia Contact

Name: Joe Walsh

Position: Project Director, Airports

Organisation: Beca Pty Ltd

Address: Level 4, 5 Queen Street, Melbourne

Telephone: 03 9272 1589

Email: [email protected]

AIRPORT CONTACT

Name: David Burns

Position: Terminal Development Manager

Organisation: Melbourne Airport

Address: Level 2, Terminal 2, Melbourne Airport, Melbourne 3045

Telephone: 03 9297 1600

Email: [email protected]

4 AAA National Airport Industry Awards 2014

Corporate Project of the Year

IntroductionMelbourne Airport’s Capital Works Program was established to meet the forecast increased future demand based on projected airline capacity requirements, and in particular, an urgent demand for aircraft parking positions at the airport. The Foxtrot Apron Infill Project was the first of a number of major airfield capital projects forming part of Melbourne Airport’s Capital Works Program to cater for increased aircraft parking demand. The Melbourne Airport Foxtrot Apron Infill Project involved the infill of the existing grass island between Taxiways Alpha, Sierra, Yankee and Golf to provide 4 additional Code C stand-off parking bays, which can alternatively accommodate 2 Code E aircraft. The design scope of the Foxtrot Apron Infill involved geometric planning, aircraft pavement, drainage, water main, landscaping, markings, apron floodlighting and associated electrical works. The design was completed by Beca in mid-2012, and the construction works commenced in September 2012 with Fulton Hogan (Main Contractor); the project achieved practical completion in November 2013. Beca undertook the design, contract administration, project management and construction monitoring of the project. The scope of work included the placement of approximately 30,000m2 of 500mm thick

Portland Cement Concrete (PCC) Heavy Duty Aircraft Pavement; installation of six new apron LED floodlight towers and associated electrical works; installation of 300m of stormwater drainage including 185m of grated drain and five flame trap structures; and construction of a new 370m section of water main line.

The apron floodlighting was required to be suitable for both Code C and Code E aircraft parking positions and complied with CASA Manual of Standard Part 139. The initial design had specified the use of traditional high pressure sodium floodlight in line with the existing apron floodlights at Melbourne Airport.

During the construction period, LED technology had developed to a level where high power LED chips were available for apron detail, and the traditional high pressure sodium floodlights were replaced by LED floodlights as an innovative energy saving measure due to the low energy consumption and high efficiency of the LED lights. The increased longevity of the LED chips helps reduce the overall maintenance and re-lamping costs of the apron floodlight system.

Melbourne Airport is the first airport in the Southern Hemisphere to introduce LED apron floodlighting technology via the Foxtrot Apron Infill Project and has now progressed this initiative for all new apron works.



5



Through a spirit and culture of teamwork including the development of a Project Team Charter, a positive and collaborative working environment was established between Melbourne Airport, Beca, and Fulton Hogan and their sub-contractors to safely and efficiently deliver a facility to a very high standard. Through this collaborative working environment, the Foxtrot Apron Infill Project was completed to the required level of quality, within budget, and two weeks ahead of programme with no Lost Time Injury (LTIs). The stands are used by a number of aircraft operators including Virgin Australia and Regional Express.

The Foxtrot Apron Infill Project has set the standard for airfield pavement infrastructure delivery at Melbourne Airport for subsequent infrastructure developments.

Melbourne Airport is the first airport in the Southern Hemisphere to introduce LED apron floodlighting technology via the Foxtrot Apron Infill Project.



7



What are the unique attributes

of the project?

The following unique design and process improvements were implemented on the Foxtrot Apron Infill Project:

• LED apron floodlighting technology

• Apron floodlight lowering headframe technology

• Enhanced concrete pavement placement and curing regimes

• Use of new data logger technology

• Melbourne Airport systems improvements

• Proactive environmental management

• Lessons learnt and knowledge sharing.

LED APRON FLOODLIGHTING TECHNOLOGY

The implementation of LED apron floodlighting on the Foxtrot Apron Infill has created a major opportunity for Melbourne Airport to experience the “white” light working environment that has enhanced safe apron operational activities. The advantages of LED technology are:

• Reduced carbon footprint for Melbourne Airport due to lower energy consumption – of the order of 50% compared to high pressure sodium lighting

• Reduced maintenance cost due to the long life of the LED fittings (50,000 hours)

• Enhanced performance as LEDs do not need to warm up on starting

• Instantaneous starting eliminates the need of dual lamps (cold standby) or additional emergency fittings to comply with CASA Manual of Standards 139 minimum lighting levels during momentary power failure.

It should be noted that the capital cost of the LED solution was higher than the traditional high pressure sodium though the relatively short payback period supported the case to implement the LED solution.

APRON FLOODLIGHT LOWERING HEADFRAME TECHNOLOGY

The apron floodlights were mounted on a headframe, which can be lowered or raised within the footprint using an electric winch system. The implementation of lowering headframe for the apron floodlights on the Foxtrot Apron Infill has improved the apron availability by negating the requirement for the closure of the apron currently required for tilted poles (to allow the pole to tilt and fall).

ENHANCED CONCRETE PAVEMENT CURING REGIMES

To achieve a high quality pavement structure to align with a 40 year pavement design life, an enhanced pavement specification was developed to include a seven day wet curing methodology and management of ambient weather conditions (hot and cold) resulting in refined working windows.

USE OF NEW DATA LOGGER TECHNOLOGY

A data logger device was used to record the concrete surface temperature within 72 hours after pour to monitor the minimum 10°C requirement during these first hours. The data logger uses an optical USB communications interface for launching and reading out the temperatures measured over a period of time. The use of this technology on the Foxtrot Apron Infill Project assisted in providing a good quality aircraft heavy duty pavement during the winter months.



9

MELBOURNE AIRPORT SYSTEMS IMPROVEMENTS

Beca worked together with Melbourne Airport in the implementation of enhanced reporting systems for Health & Safety management and incident reporting. The Foxtrot Apron Infill Project provided the platform for the development of access protocols and traffic management templates, which have now become the standard for airside infrastructure projects at Melbourne Airport.

PROACTIVE ENVIRONMENTAL MANAGEMENT

The Foxtrot Apron Infill Project was elected for an external Melbourne Airport environmental audit with a very positive outcome and zero non-conformances. Both the Fulton Hogan and Beca teams obtained Green Card Training for site team members to enhance their environmental awareness in dealing with construction activities and the Environmental Management Plan

LESSONS LEARNT AND KNOWLEDGE SHARING

A monthly cross-contract meeting was carried out with relevant Beca personnel from all Melbourne Airport airfield projects with the purpose of sharing knowledge acquired from specific Melbourne Airport issues.

A “lessons learnt” register was developed based on discussions during these meetings and was shared across the Beca Airports sections in Australia and New Zealand. Consistency across the Melbourne Airport projects was also established during the cross-contract meetings.

The sharing of the lessons learnt across the various airfield projects has resulted in better outcomes and added value to the Melbourne Airport airfield assets.

This initiative extended to the creation of a Contractor’s OHS Forum across a number of active airfield projects, which facilitated knowledge sharing with a specific focus on OHS.

“The Foxtrot Apron Infill project has achieved all of the project objectives by completing the works on programme, safely (No LTIs), within budget and to high standard incorporating innovation with the implementation of LED lighting technology.”

- Henry Ashton, Project Manager, Melbourne Airport





11



The Beca Group is a leading international engineering and related consultancy services organisation, specialising in the design and management of projects. Beca has over 3,000 employees working on international projects across Asia Pacific; the main hubs are Australia, New Zealand and Singapore.

Beca has provided design and project management services to the aviation industry for over 30 years, delivering projects on regional and international commercial airports and defence airfields throughout the Asia-Pacific region.

Beca offers planning, design and management services to support core airport activities, and draws on deep project experience. This, include the award-winning Melbourne and Adelaide Airport runway overlay projects, the design of airfield pavement maintenance works for over 25 Australian defence airfields, the Integrated Terminal Project at Christchurch International Airport, Singapore’s Changi Airport Terminal 4, and various major Auckland Airport Terminal Building projects.

Beca also has intimate knowledge of the design and construction aspects of apron and taxiway projects, including the recent International Apron

and Taxiway Expansion (IATE) Project at Brisbane Airport, the Air Transport Apron Reconstruction project at RAAF Base Edinburgh, the Southern Apron Expansion and Sierra Apron Infill Project at Melbourne Airport, and major concrete slab replacement projects at Auckland and Melbourne Airports.

Beca’s Airfield Lighting Team has substantial experience in Australia and New Zealand, having delivered airfield lighting design for major international airports at Australia and overseas. The team offers feasibility study, design and construction supervision as well as associated electrical services design for power distribution, lighting control and cable management system for the airport lighting.

About Beca

Beca has provided design and project management services to the aviation industry for over 30 years...



13

AUSTRALIA

• Project management, design and construction monitoring for the Southern Apron Expansion and Sierra Apron Infill Project at Melbourne Airport

• Project management, design and construction monitoring for the Papa, Uniform and Golf Taxilanes Slab Replacement project at Melbourne Airport – involves the largest use of Rapid Set Cement Concrete on an Australian airport to date

• Design consultant for the Australia Department of Defence National Aircraft Pavement Maintenance Project since 2009

• Airfield pavement maintenance advice to Adelaide, Brisbane, Darwin and Gold Coast Airports.

HONG KONG

• Airfield pavement peer review role with Atkins China Ltd as part of the Scheme Design Stage for the new Third Runway P283 project.

SINGAPORE

• Building and IT services design for Changi Airport’s new Terminal 4.

PACIFIC ISLANDS

• Various airfield projects throughout the Pacific Islands.



NEW ZEALAND

• Recent and current runway overlay programmes at Dunedin, Hamilton, Gisborne and Palmerston North Airports

• Terminal, airfield and landside works at Wellington International Airport and preparation of a digital ground terrain and obstacle surface models to help manage the airport’s obstacle environment

• Preparation of the 2014 Airport Master Plan and the concept design for the Terminal Expansion Project at New Plymouth Airport

• Airfield and terminal building works at Auckland Airport – the airfield works incorporate the use of recycled asphalt and concrete pavement materials

• Airfield pavement planning and design at Christchurch International Airport.

PAPUA NEW GUINEA

• Lead consultant for the Asian Development Bank funded National Airfields Program (11 airfields).



15



17

The key challenge for the Foxtrot Apron Infill Project involved working on a site surrounded by operational taxiways. To minimise the impact of the works on airport operations, it was imperative to stage the Contractor’s access to the site. Each stage had to be handed back to Melbourne Airport on the programmed date before the next stage was released for works. This was achieved through the main contractor, project manager, construction monitor and the designer working closely, smartly and efficiently.

Further, the Foxtrot Apron Infill Project interfaced with a HV Cable Replacement Project and the Foxtrot works area had an Exclusion Zone in place until the cable replacement was complete. Commissioning issues for the HV Cable meant that the exclusion zone was not lifted as programmed, affecting the construction progress on the Foxtrot Apron Infill site. However, Fulton Hogan together with Beca, worked in a collaborative manner to minimise the impact on program.

The poor natural ground conditions presented a challenge that resulted in overcut of large parts of the work area. The soft spot treatment methodology had to adapt to deal with this issue.

Project Challenges



The Foxtrot Apron Infill Project included a number of innovative technologies to achieve maximum operational efficiency of the apron. Technologies included use of LED lighting and lowering headframe light towers, improving the stand availability and hence the operational performance of the aprons.

Melbourne Airport, Fulton Hogan and Beca recognise their environmental responsibilities and the importance of sustainability in the construction, maintenance and operation of the projects and adopted sustainable solutions where possible (e.g. LED flood lighting described above, proactive environmental management).

Systems to manage dust and noise arising from the works were identified by Beca and implemented by Fulton Hogan to ensure that the construction works did not impact the surrounding environment or the airfield operations.

As noted above, the Foxtrot Apron Infill Project underwent an external Melbourne Airport environmental audit and zero non-conformances were noted.

New Applied Technologies

Environmental Responsibilities

Care is one of Beca’s four core values, and all personnel involved in the project shared a commitment to putting safety first.

During the Design Phase, Safety in Design principles were employed, identifying and eliminating, isolating or minimising potential Health & Safety risks. This process included a Safety in Design workshop, which was held between Beca and Melbourne Airport; this generated amendments to improve construction, and operational and maintenance safety for inclusion in the final design.

During construction, a Health & Safety culture was created across the Melbourne Airport, Fulton Hogan and Beca teams through regular dialogue, daily toolbox meetings, interactive safety sessions and talks during weekly site meetings. This approach underpinned the Project Team Charter.

Commitment To Safety

The Foxtrot Apron Infill Project included many innovative technologies to achieve maximum operational efficiency of the apron.



19



21

To promote a successful project culture, Beca led the establishment of a Project Team Charter specific to the Foxtrot Apron Infill Project.

The Charter, developed collaboratively by Melbourne Airport, Fulton Hogan and Beca, set a project vision, benchmarks and expected behaviours from all parties and individuals.

Project Team Charter and Collaborative Working

www.beca.com

AAA National Airport Industry Awards 2014 BECA Pty Ltd

Documents

Transcript of AAA National Airport Industry Awards 2014 BECA Pty Ltd