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PAVEMENT DESIGN
3.1
INTRODUCTION
Volume 2 Exhibit D Special Specifications Part DI Employers Requirements
details the following salient consideration for the airfield pavements:
1.
The pavement design for the various airfield elements shall comply with the
Federal Aviation Administration FAA standards and proposed practices.
2.
3.
4.
5.
The airfield fleet mix using KAIA shall be analyzed and generated for the
design life, taking into account the annual growth in air traffic.
6.
The distribution of the aircraft loading around the various zones of the
airport and consequently the anticipated load on each airfield element shall
be determined separately.
7.
The airfield pavement design shall be carried out using the latest state-ofthe-art computer programs (software) that cater for the large body aircraft
wheel configuration such as the A380, A340, B777, B747, AN225, etc. and
that can account for the wander effect in order to optimize the resulting
pavement thicknesses. Fatigue equations shall conform to the
requirements of the US Corps of Engineers for asphalt concrete and
granular materials and subgrade and to those of the Portland Cement
Association for cement concrete.
8.
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3.2
BASIS OF DESIGN
3.2.1
Overview
The pavement design for the aircraft pavements associated with the development
of the Saudi Aerospace Engineering Industries Aircraft Maintenance Hangars,
Jeddah - individual hangar pavements, external apron, Taxiway MA and Taxilane
LB, has considered a range of factors including:
The existing site conditions
Existing subsoil conditions
Proposed operating conditions
Current and proposed aircraft types
Aircraft wheel and body jacks
Aircraft tugs
Emergency service vehicles
Concrete strength
This report presents a summary of the key assumptions and input data used to
develop the designs for the individual hangar pavements, external apron,
Taxiway MA and Taxilane LB in terms of:
Aircraft loads
Aircraft tug loads and operating frequency
Aircraft jacking operations
Frequency of operations
Subsoil strength
Concrete strength (for rigid) pavements
Emergency service vehicle loads and operating frequency
A number of design scenarios have been considered in developing the pavement
thicknesses. These design scenarios were undertaken to test the sensitivity of
the pavement thickness for both rigid and flexible pavements to variations in the
design assumptions in terms of:
Frequency of aircraft operations
Frequency of jacking operations
Subsoil strength
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The results of the individual analyses are summarized in this report, while
complete details are included in Appendices C and D.
3.2.2
Pavement Types
Flexible Pavements
Flexible pavements generally consist of a dense, hot mix asphalt surfacing
placed on an unbound crushed aggregate base and/or aggregate sub-base
courses), and the pavement is then supported by the subgrade. The design for
Saudi Aerospace Engineering Industries Aircraft Maintenance Hangars is being
carried out using the U.S. Department of Transportation Federal Aviation
Administration (FAA) design program FAARFIELD, used in conjunction with the
FAA Advisory Circular (AC) 150/5320-6E. This AC includes guideline
requirements for the various materials for the pavement layers. Where the AC
requires engineering judgement regarding the material to be used this is detailed
and justification for the choices made is given.
For flexible pavement design, FAARFIELD uses the maximum vertical strain at
the top of the subgrade and the maximum horizontal strain at the bottom of the
asphalt surface layer as the predictors of pavement structural life. FAARFIELD
provides the required thickness for all individual layers of flexible pavement (in
this case surface, base and sub-base) needed to support a given aircraft traffic
mix over a particular subgrade for the given design period.
Rigid Pavements
The basic composition of an airfield rigid pavement is a Portland cement concrete,
PCC (which is often referred to as Pavement Quality Concrete PQC), on a
granular or stabilised sub-base supported on the in-situ subgrade after suitable
compaction. The purpose of a base course under a rigid pavement is to provide
uniform stable support for the pavement slabs, and support across the joints. A
minimum thickness of 100mm of base is required under all rigid pavements.
According to FAA, stabilized materials are required for a base course under rigid
pavements serving airplanes weighing 45,359kg or more to improve load transfer
across joint lines and reduce pumping type erosion effects due to flexure of the
slabs at the joint lines.
For rigid pavement design, FAARFIELD uses the maximum horizontal stress at
the bottom edge of the PQC slab as the predictor of pavement structural life. The
maximum horizontal stress for design is determined using an edge loading
condition with approximately 30% load transfer to the adjacent slab.
Once load transfer exceeds 40% across a joint line the interior thickness of the
slab then becomes the critical element. Localised thickened edges are required
at transitions from concrete to asphaltic surfacing or at box outs for manholes,
service pit, grated drains, etc. FAARFIELD provides the required thickness of the
rigid pavement slab needed to support a given aircraft traffic mix over a particular
subgrade/base course for the given design period. The life of the concrete
surfacing is very sensitive to changes in slab thickness, and the stiffness of the
immediate supporting layer.
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2.
3.
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4.
5.
Wide body paint and wash hangars shall be designed to receive all wide
and narrow body aircrafts except the A380.
6.
A380 paint and wash hangars shall be designed to receive all types of
aircrafts.
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3.2.4
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Body jacking operations are based on one (1) aircraft being jacked
per month or 12 annual jacking operations.
Wheel jacking operations are based on one (1) jacking operation per
landing gear assembly per month or 12 annual wheel jacking
operations.
Body jacking operations are based on one (1) aircraft being jacked
ever three (3) weeks or 18 annual jacking operations.
Wheel jacking operations are based on one (1) jacking operation per
landing gear assembly every three (3) weeks or 18 annual wheel
jacking operations.
Body jacking operations are based on one (1) aircraft being jacked
ever three (3) weeks or 18 annual jacking operations.
Wheel jacking operations are based on one (1) jacking operation per
landing gear assembly every three (3) weeks or 18 annual wheel
jacking operations.
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Body jacking operations are based on one (1) aircraft being jacked
per month or 12 annual jacking operations.
Wheel jacking operations are based on one (1) jacking operation per
landing gear assembly per month or 12 annual wheel jacking
operations.
--
-
--
Wash Hangar 1
730
Wash Hangar 2
730
Paint Hangar 1
61
Paint Hangar 2
61
12
12
12
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
18
12
12
12
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--
-
--
12
12
12
12
12
12
12
12
12
12
12
12
365
1,460
365
1,460
Note:
3.2.5
One aircraft operating in and out of the hangar is equivalent to two movements
for the purposes of pavement design.
Aircraft Jacks
Body Jacks
Two types of body jacks have been adopted, these being inner main wing jacks
and remainder of fuselage and outer wing jacks. All jacks are assumed to be
pneumatic tripod jacks with circular base plates. The following jack details have
been assumed in the development of the pavement design for the hangars:
Main wing jacks assumed base plate diameter = 300mm
Forward fuselage jack - assumed base plate dimension = 300mm
Rear fuselage jack assumed base plate dimension = 300mm
Reminder of jack positions assumed base plate diameter = 300mm
Wheel Jacks
For all wide body aircraft, the wheel jacks have been assumed as 225mm x
450mm for the main landing gear and nose landing gear.
For all narrow body aircraft, the wheel jacks have been assumed as 200mm x
450mm for the main landing gear and 125mm x 300mm for the nose landing gear.
3.2.6
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A318
6,800
6,000
33,400
n/a
n/a
A319
6,800
2,000
33,400
n/a
n/a
A320-100
6,800
2,000
33,400
n/a
n/a
A320-200
6,800
2,000
33,400
n/a
n/a
A321-100
6,800
2,000
33,400
n/a
n/a
A321-200
6,800
2,000
33,400
n/a
n/a
A330-200
11,135
4,500
73,446
n/a
n/a
A330-300
11,135
4,500
73,446
n/a
n/a
A340-200
12,300
4,500
80,982
n/a
n/a
A340-300
12,300
4,500
81,084
n/a
n/a
A340-500
18,000
9,000
96,000
n/a
n/a
A340-600
18,000
9,000
96,000
n/a
n/a
A350-800
no data
no data
no data
n/a
n/a
A350-900
no data
no data
no data
n/a
n/a
A350-1000
no data
no data
no data
n/a
n/a
A380-800
51,000
12,000
190,000
n/a
n/a
B737-600
7,900
9,900
31,700
n/a
n/a
B737-700
7,900
9,900
31,700
n/a
n/a
B737-800
7,900
9,900
31,700
n/a
n/a
B737-900
7,900
9,900
31,700
n/a
n/a
B737-900ER
7,900
9,900
31,700
n/a
n/a
B747-300
17,900
43,900
90,700
13,600
11,300
B747-400
17,900
43,900
90,700
13,600
11,300
B757-200
12,200
1,800
49,200
n/a
n/a
B757-300
12,200
1,800
49,200
n/a
n/a
B767-200
12,700
30,400
68,000
9,500
n/a
B767-200ER
12,700
30,400
68,000
9,500
n/a
B767-300
12,700
30,400
68,000
9,500
n/a
B767-300ER
12,700
30,400
68,000
9,500
n/a
B767-400ER
12,700
30,400
68,000
9,500
n/a
B777-200
20,400
44,9900
94,300
10,000
7,800
B777-200ER
20,400
44,9900
94,300
10,000
7,800
B777-300
25,900
57,100
119,000
12,700
9,900
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B777-300ER
25,900
57,100
119,000
12,700
9,900
B787-9
20,000
37,200
77,600
8,200
5,400
MD-11F
27,800
n/a
109,100
n/a
3,600
The wheel jacking loads have been determined by adopting the proposed aircraft
design loads, the percentage of the design aircraft mass on the landing gears
and the number of wheel jacking points on the undercarriages of the individual
aircraft.
The distribution of the wheel jacking operations has been assumed as distributed
as 80% on the main undercarriage (split 50/50 each side) and 20% on the nose
wheel.
For aircraft with a centre main landing gear, the distribution of the wheel jacking
operations has been assumed as distributed as 30% on the each of the main
landing gears, 25% on the centre landing gear and 15% on the nose wheel.
3.2.7
Aircraft Tug
The following tender query has been raised in relation to aircraft tugs, the
clarification of which is pending.
In addition to the data on fire tenders and other emergency vehicles (RFI Register No
28), additionally we require details of the aircraft tugs likely to be used by Saudi
Aerospace.
The following data related to the aircraft tug has been assumed for the
development of the pavement design for the hangars pending clarification of the
tender query:
Wide Body Aircraft
The assumed operating mass of the tug is 50,000kg.
The assumed operating tyre pressure is 520kPa.
Movements are based on four (4) movements (on average) in and around the
hangar per aircraft.
Narrow Body Aircraft
The assumed operating mass of the tug is 30,000kg.
The assumed operating tyre pressure is 520kPa.
Movements are based on four (4) movements (on average) in and around the
hangar per aircraft.
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3.2.8
The following data related to the emergency services vehicles has been assumed
for the development of the pavement design for the hangars pending clarification
of the tender query:
The emergency services vehicle is assumed to be a 6 wheel Panther or
similar.
The assumed operating mass of the emergency service vehicle is 40,000kg.
The assumed operating tyre pressure is 1,000kPa.
3.2.9
Subgrade Strength
As discussed in Section 2, the pavement design is based on a CBR of 15%. The
sensitivity of pavement thickness to a reduction in the CBR has been assessed
with CBR 10%.
The rigid pavements are designed for a modulus of subgrade reaction, equivalent
to CBR 15%. The modulus of subgrade reaction, or k value, can be calculated
approximately from the CBR value using the equation:
k = (1500 x CBR/26)0.7788
This gives a value in pci (pounds per cubic inch). For the 15% CBR, the k value is
calculated as 194 pci, which converts to 52.4 MN/m3. Similarly, the modulus of
subgrade reaction equivalent to a CBR of 10% is 38.4 MN/m3.
This report has been prepared on the basis of construction of the fill embankment
to provide a stable, uniform subgrade with an equivalent minimum CBR of 15%.
Insitu testing will be required to confirm that such works have been completed as
specified prior to pavement works commencing.
3.2.10
Concrete Strength
The specification (Section 321313) issued with the Tender Documents nominates
a design flexural strength of 4.6 MPa at 28 days.
Load transfer will take place through the provision of dowel bars through the
doweled construction joints and sawn contraction joints.
3.2.11
Design Period
The design period for the pavements (both rigid and flexible) has been assumed
as 30 years.
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3.3
PAVEMENT DESIGNS
3.3.1
Taxiway MA
Taxiway Pavement
All aircraft entering or leaving the facility will access Taxiway MA, entering the
apron initially. Aircraft are assumed to enter the taxiway at OEW + 50% fuel and
park on the apron. Aircraft are assumed to leave the apron (departing the
maintenance facility) at OEW + 50% fuel.
The exception to this is the length of taxiway to the paint hangars and wash
hangars. The aircraft using this portion of the taxiway are assumed to be at OEW
+ 10% fuel maximum.
To simplify the analysis at this stage, a uniform pavement thickness is proposed
for Taxiway MA along its length.
The total number of aircraft entering the facility on an annual basis is derived
from the annual usage of each of the maintenance hangars annually. These
same aircraft are assumed to leave the facility annually.
The previous pavement design proposed a pavement structure of 60mm PMB on
60mm Binder Course on 200mm CABC on 250mm CASBC based on the
assumptions made at the time.
Based on the clarifications in Notice to Tenderers No 11, the pavements have
been redesigned. Table 3.5a provides the pavement thickness requirements for
varying subgrade strengths and operational scenarios.
Table 3.5a
Double Aircraft
CBR 15%
60mm PMB on
60mm Binder Course
200mm CABC
305mm CASBC
60mm PMB on
60mm Binder Course
200mm CABC
325mm CASBC
CBR 10%
60mm PMB on
60mm Binder Course
200mm CABC
445mm CASBC
60mm PMB on
60mm Binder Course
200mm CABC
475mm CASBC
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