Excellence in Underground Awards – Excavation/Site Development Winner
Runway Reconstruction & RSA Improvements
[EDITOR’S NOTE: In each issue, Utility Contractor profiles NUCA‘s Excellence in Underground winners. The projects recognize challenging, innovative, or unique projects completed with excellent results. To nominate your project for an Excellence in Underground Award, click here.]
The Runway Reconstruction and RSA Improvements project for the Maury County Regional Airport Authority in Tennessee, consisted of rehabilitating the entire 6,000 linear foot runway and grading the runway safety area. The project consisted of 20,241 cubic yards of excavation, 14,169 linear feet of ADS underdrain pipe, 74,379 square yards of cement treated soil reclamation, 20,161 tons of P-401 Asphalt, pavement markings, new airfield lighting including an electrical vault building, 21 acres of hydro mulch, and 12,314 square yards of sod.
As we all know in the construction industry, market volatility can, and far too often does, negatively impact the contractor. The first challenge presented to contractor Cleary Construction after being awarded the contract was in the procurement phase. Since this project would not start construction until Spring 2023—over 13 months after submitting the bid—Cleary immediately began working with subcontractors and suppliers to secure the materials necessary for construction and to avoid price escalations. Even with the start date coming 13 months after the bid, Cleary can proudly say, no price escalation was passed on to the owner.
The next challenge Cleary faced was in the pre-construction phase. The 21-acre site yielded two environmentally protected wetland areas and one just outside the airport’s property. To understand this project’s environmental impact, Cleary conducted both a wetland delineation and hydraulic determination of the project site. The information obtained from the study allowed Cleary to implement an improved erosion control plan to protect these areas. Cleary worked closely with TDEC’s Columbia Field Office, Garver USA, Tennessee Aeronautics Division, ECS Southeast, LLP., and Kimberly, Inc. throughout this process.
The biggest challenge Cleary faced was in the construction phase. The full-depth cement treated subgrade reclamation, also known as “FDR,” presented several unknowns to Cleary and FDR subcontractor Pozzolanic before ground was broken. The entire 6,000 linear feet runway surface area and all five partial taxiway connectors were to be pulverized, treated with cement, and graded to within 0”+ to -1/2”. Garver, the engineer assisting construction operations for MCRAA, conducted several preliminary subsurface soil investigations prior to construction. The initial results indicated potential subgrade information such as: asphalt and base stone thicknesses of the runway surface. This information is very critical in the FDR process to determine the cement content needed to achieve the desired strength of the subgrade. Once the runway was pulverized in-place to a depth of 16 inches, Cleary obtained several samples of the material. Cleary worked closely with ECS to generate a mix design. The results generated three different mixtures of soil, asphalt, base stone, and cement content throughout the nearly 75,000 square yard area. Cleary worked closely with Pozzolanic, ECS, Garver, and TAD to monitor the data results and adjust the mixture as needed throughout the course of the FDR process. Accuracy during this step is essential for this scope of work and its impact on the overall success of the project.
Project Partners
To complete this project in a timely manner for MCRAA, Cleary Construction Inc. worked with multiple trusted suppliers and subcontractors on this project. Cleary partnered with Pozzolanic Contracting & Supply Co., Inc. from Knoxville, TN, to perform the cement treated soil stabilization. Wright Paving Contractors, Inc. from Fayetteville, TN, performed the P-401 asphalt paving in addition to the double bituminous chip seal layer. Appalachian Foothills Contracting, Inc. out of Lexington, KY, installed the new runway lighting system and electrical vault building. On a project where grade was critical, Cleary partnered with Bridgepoint, LLC. from Mt. Juliet, TN, to build the site’s GPS model. Bridgepoint also handled surveying and site layout, as well as as-builts and grade checks throughout the entire duration. ECS Southeast, LLP. performed quality control testing on every phase of the project. American Stripers from Columbia, TN, performed the temporary and permanent pavement markings on the runway surface. Kimberly, Inc. out of Sparta, TN, installed temporary erosion control measures and performed the final site stabilization. Core & Main supplied the ADS underdrain pipe and necessary appurtenances. Infrastructure Precast, Inc. out of Beaver Dam, KY, supplied the pre-cast underdrain headwalls. BC Cannon supplied the airfield closure devices which included temporary X’s for both runways and the low-profile barricades installed along the apron area. Rogers Group, Inc. of Columbia, TN, supplied the aggregate stone backfill for the underdrain pipe. Hanes Geo out of Goodlettsville, TN, supplied the geo-textile fabric.
Project Benefits
Airports attract new business developments and economic growth to rural areas. This is evident in Maury County, TN, where a new, state of the art, battery plant facility is currently being constructed. Airports are limited on the avenues where revenue can be generated. Most airport’s main revenue source is through the sale of fuel. Re-opening the runway on time was very important to the Maury County Regional Airport Authority and its tenants. Cleary can proudly say the airport was re-opened within the 120-day contract time. This airport, now fully refurbished, will only enhance Mt. Pleasant’s economy and continue to benefit the community for years to come.
“As the Engineer of Record for Maury County Regional Airport, Garver knows the importance of completing critical projects with a high level of quality while maintaining tight schedules and budgets,” according to Zac Simpson, P.E., Senior Project Manager for Garver.
“The Runway Reconstruction and RSA Improvements Project at Maury County Regional Airport was one such recent example. Cleary Construction was awarded the bid for this project in August of 2022 but was not issued a Notice to Proceed until the following May. The initial project bid was submitted in April 2022. The difference in time between bid submittal and Notice to Proceed produced a financial challenge that Cleary overcame by avoiding additional cost hikes to the Maury County Airport Board.
“With construction costs in constant flux, the meeting of this challenge is to be commended. This project presented challenges in the pre-construction and construction phases as well. Cleary coordinated all environmental procedures needed to ensure that the project was compliant with federal regulations and protected two wetland locations on-site. Cleary also worked alongside other subcontractors to develop an adequate mix design utilizing full depth reclamation methodology. Due to the size of the project footprint, three different mix designs were used, and adjustments were required in the field to ensure strength was maintained.
“Throughout the project, Cleary worked to remain on schedule to ensure that the airport was closed no longer than set forth in the contract documents while also providing a good end product to serve the airport for years. Maury County Regional Airport has a large economic impact on the area with various manufacturers calling the area home. By helping to complete this runway reconstruction and safety area improvements, Cleary has offered safety and operational benefits to this airport and to the community by extension.”
Project-at-a-Glance
- Project: Runway Reconstruction & RSA Improvements
- Category: Excavation/Site Development
- Project Owner: Maury County Regional Airport Authority
- Contractor: Cleary Construction
- Location: Mt. Pleasant, Tennessee
- Value: $8,233,576.75
- Bid: April 2022
- Awarded: August 2022
- Notice to Proceed: May 2023
- Completed: September 2023
