Airport Construction David H Moloney

Shown using 3D Animations, Footage & Images. 10th June 2016

Brief Description

The purpose of this presentation is to give an

understanding of the Methods, Plant and
Sequence to construct an Airport.

This presentation can be used to engage

Stakeholders and to get the Site Teams
commitment to the programme.

Also can be used for Induction Training and as a

way to capture and share knowledge.

High in Educational Value and easily

understood.

This Video Presentation is innovative and has

many beneficial uses.

Pause to read the details on the slides.

ⓒ David H Moloney
Table of Contents
General Items
General Items
Contractor’s Temporary Site Facilities

Brief Description

Contractors Site facilities comprise:

Offices, Canteens, Toilets, Drying Rooms,
Stores, Plant Yard, generators and
Workshops.

ⓒ David H Moloney
General Items
Contractor’s Temporary Site Facilities

ⓒ David H Moloney
General Items
Contractor’s Camp for 8,000 persons

ⓒ David H Moloney
General Items
Sheet Pile Temporary Shaft

Brief Description

Sheet Pile Temporary shaft is used to enable an

excavation for a deep structure.
The construction sequence is:
Install sheet-piles.
Excavate and install bracing.
Excavate to final level.
Construct concrete structure.
Backfill, remove bracing and sheet-piles

ⓒ David H Moloney
General Items
Sheet pile Temporary Shaft

3D Animation to show Sequence

ⓒ David H Moloney
General Items
Dewatering

Brief Description

Construction dewatering is the removal or drainage of

groundwater and or surface / rain water usually by
pumping to keep the works dry.

ⓒ David H Moloney
General Items
Dewatering

ⓒ David H Moloney
General Items
Dewatering by Wellpoints

ⓒ David H Moloney
General Items
Water Pollution Prevention

Brief Description

Pumped and rain water that is contaminated with clay and

silt needs to be treated prior to discharge from site.
Settlement ponds and settlement tanks are two methods

ⓒ David H Moloney
General Items
Dewatering by Settlement Lagoon

ⓒ David H Moloney
General Items
Water Pollution Prevention
General Items
Temporary Fence type 1

Brief Description

Examples of temporary security

fences that are higher than the
usual

ⓒ David H Moloney
General Items
Temporary Fence type 1

ⓒ David H Moloney
General Items
Temporary Fence type 2

Brief Description

Temporary fence on precast beam for airport.

ⓒ David H Moloney
General Items
Temporary Fence type 2

ⓒ David H Moloney
General Items
Site Hoarding examples

ⓒ David H Moloney
General Items
Falsework
Brief Description

Falsework to support Bridge deck formwork

General Items
Climbing Tower Cranes

Brief Description

A climbing tower crane lifts itself up using a climbing

attachment with hydraulic jacks that surrounds the mast.
The climbing attachment lifts itself up off the erected mast
and inserts a new mast section.

Rail mounted Tower Cranes layout plan and photographs for

airport passenger terminal building, showing the tower
cranes locations, rail track travel range and working area
coverage.
 Climbing Tower Cranes
Miscellaneous
General Items
Climbing Tower Cranes
General Items
Tower Cranes Layout
General Items
Tower Cranes on Rails
Staff Offices for Departments

Department Functions
Planning Planning & Progress Monitoring
HSSE Health, Safety, Security & Environmental
Quality Assurance Quality Control
Procurement Materials & Subcontractors
Engineering Shop drawings & submissions
Quantity Surveying Monthly & final accounts
Document Control Distribution of Construction Information to Site Team
Plant & Equipment Hiring, Fuelling & Maintenance of Plant
I.T. Computers, software & Internet
Administration Payments
Human Resources
 Site Laboratory
General items
General Items
Traffic Management

Brief Description

Traffic management plans are

necessary when working on or beside
roads

ⓒ David H Moloney
General Items
Traffic Management - Realign Motorway under new Bridges

ⓒ David H Moloney
General Items
Traffic Management - Realign Motorway under new Bridges

ⓒ David H Moloney
General Items
Traffic Management – Divert Live Traffic onto Realigned Carriageway

ⓒ David H Moloney
General Items
Temporary Roads & Entrances

ⓒ David H Moloney
General Items
Site Layout & Locations of Temporary Facilities

ⓒ David H Moloney
Geotechnical
Geotechnical
Vibro Compaction - Sequence, Plant & Methods

Brief Description

Vibro compaction is used to compact granular

ground to improve its load bearing capacity and
reduces the seismic liquefaction potential. Used
for the Palm Islands in Dubai.
A vibrator suspended from a crane is used and
inserted to a triangular grid pattern.

ⓒ David H Moloney
Geotechnical
Vibro Compaction - Sequence, Plant & Methods

ⓒ David H Moloney
Geotechnical
Stone Columns ⓒ David H Moloney

Brief Description

Stone columns are used to improve the load

bearing capacity of ground.
Top feed vibrators suspended from an excavator or
crane along with loading shovels are used.
The stone columns are constructed to a triangular
grid pattern.
Geotechnical
Stone Columns

ⓒ David H Moloney
Earthworks
 Much Shifting
Earthworks

Brief Description

Muck Shifting is the process of moving

large quantities of soil and rock.
 Excavate & Load, Cart, Tip & Return
Earthworks

Brief Description 7 minutes

Cycle Time for 7km haulage distance

using an Excavator 45 tonne weight
and Dumper with a 40 tonne capacity,
the cycle time is 34 minutes

7 km

14 minutes 7 km 14 minutes

3 minutes
Earthworks
Spreading & Compaction
Earthworks
Spreading & Compaction
 Rock - Excavability
Earthworks

Brief Description

The excavability of rock depends

mainly on the rock strength and the
layer thickness. This diagram shows
excavation methods for rock of
various strengths and thicknesses,
with a free face.

ⓒ David H Moloney
Earthworks
Rock-breaking
Earthworks
Rock-breaking
Earthworks
Rock Drilling & Blasting – Road Cut
Earthworks
Mass Haul Diagram

Brief Description

Shows the quantities and location of

excavation and fill quantities for
motorway.
 Existing Underground Utilities
Earthworks

Brief Description

Before digging
establish the location
and route of
underground cables.

Locator to find Utilities ⓒ David H Moloney

 Existing Underground Utilities & Overhead Cables - Safety Measures
Earthworks

ⓒ David H Moloney
Earthworks
Crushed Aggregate Base Course

Brief Description

Crushed Aggregate Base Course

CABC mixing and Laying
Earthworks
Crushed Aggregate Base Course

Brief Description

Crushed Aggregate Base Course

CABC mixing and Laying
Earthworks
Mixing CABC
Earthworks
Spreading & Compaction CABC
Earthworks
Spreading & Compaction CABC
Concrete
 Concrete Batching Plant David H Moloney
Concrete

Brief Description

Concrete batching plant comprises -

concrete mixer, control cabin, silos for
cement and fly ash, aggregate bins and
conveyor belt system to feed the mixer.
Also aggregate storage bays and water
storage tanks.

ⓒ David H Moloney
 Concrete Batching Plant
Concrete

ⓒ David H Moloney
 Concrete Batching Plant
Concrete

ⓒ David H Moloney
 Concrete Batching Plant – Computer Controlled
Concrete

ⓒ David H Moloney
 Concrete Batching Plant - Liebherr Betomix Animation
Concrete
 Concrete Batching Plant David H Moloney
Concrete

Brief Description
.
The mixing is computer controlled
and has a dynamic screen display,
showing the process. The material
storage capacity is, to match two
days concrete production.

ⓒ David H Moloney
 Quarry & Aggregate Production
Concrete

Brief Description

Quarry and Aggregate Production. Rock is

blasted free from a quarry face and fragmented.

The blasted rock is crushed and screened to

produce different size ranges of aggregates

ⓒ David H Moloney
 Quarry & Aggregate Production
Concrete

ⓒ David H Moloney
 Quarry - Drilling Holes for Explosives
Concrete

ⓒ David H Moloney
 Quarry - Placing Explosives in Holes
Concrete

ⓒ David H Moloney
 Quarry - Blasting
Concrete

ⓒ David H Moloney
 Aggregate Production Capacity 300 tonnes per hour
Concrete

ⓒ David H Moloney
 Quarry Plant & Outputs
Concrete
 Reinforcement Cutting & Bending Yard
Concrete

Brief Description

Reinforcement in 12 m lengths.
Delivery in 3 ton Bundles

ⓒ David H Moloney
 Reinforcement Cutting & Bending
Concrete

ⓒ David H Moloney
 Reinforcement Cutting & Bending
Concrete

ⓒ David H Moloney
 Reinforcement Cutting & Bending Yard David H Moloney
Concrete

Reinforcement in 12 m lengths. Delivery in 3 ton Bundles Reinforcement cut to length by Shearing Machine

Reinforcement Bent to Shape by Bending Machine Reinforcement that is cut and bent is Bundled for delivery to work site
ⓒ David H Moloney
 Reinforced Wall Construction Sequence
Concrete

Brief Description

The sequence to construct a reinforced concrete wall is as

follows:
Tie the reinforcement.
Erect stop-ends and the wall shutters.
Pour and vibrate the concrete mix.
Remove the shutters after the concrete has hardened.

Cycle Time
Pour per Day

ⓒ David H Moloney
 Reinforced Wall Construction Sequence
Concrete

ⓒ David H Moloney
 Reinforced Structure Construction Sequence
Concrete

Brief Description

The general sequence to construct a reinforced concrete tank

is as follows-
1. Construct the floor and wall panels in a hit and miss pattern.
2. Construct the floor and wall corners and T shape panels.
3. Construct the roof working outwards from the back.

ⓒ David H Moloney
 Reinforced Structure Construction Sequence
Concrete

ⓒ David H Moloney
 Reinforced Construction Tank, Construction Sequence David H Moloney
Concrete

ⓒ David H Moloney
 Bridge & Post-tensioning
Concrete

Brief Description

The sequence to post-tension a bridge

deck is as follows;
Fix the ducts and anchorages.
Install the stressing strand.
Concrete the deck.
Stress the strands and lock at
anchorages.
Grout the ducts.
 Bridges on Project
Concrete
 Bridge & Post-tensioning
Concrete
 Bridge & Post-tensioning
Concrete
 Bridge Concrete Deck
Concrete
 Bridge Concrete Deck
Concrete
 Bridge Post Tensioning Deck – Install Strand
Concrete
 Bridge Post Tensioning Deck
Concrete
 Bridge Construction Sequence David H Moloney
Concrete

ⓒ David H Moloney
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Tower Construction
Concrete

Brief Description

Air Traffic Control Tower constructed

using a jump-up shutter system.
 Tower Construction Climbing Shutter
Concrete

Cycle Time 3 Days

 ATC Tower Cladding
Concrete
 Culvert Construction
Concrete

Brief Description

Sequence to construct culvert

with head walls.
 Culvert Construction
Concrete
 Oil Interceptor
Miscellaneous
 Waterproofing Spray on System
Miscellaneous
 Waterproofing Spray on Tests
Miscellaneous
Pipework
 Central Utility Yard
Miscellaneous
 Chiller Building
Provides chilled water for Air Conditioning
Miscellaneous
 Chiller Plant
Provides chilled water for Air Conditioning
Miscellaneous

BIM
Chilled Water Storage Tank

Chiller Building Cooling Towers

 Chiller Building
Provides chilled water for Air Conditioning
Miscellaneous

Chiller Building
 Pipe Spools Fabrication
Pipework

Brief Description

Spools are fabricated from pipes and fittings .

 Spool Fabrication on site
Pipework
 Pipe Spool Fabrication Workshop
Pipework
 Spool Fabrication - Pipe Rolling & Cutting Table
Pipework
 Spool Fabrication Spool Rolling & Welding
Pipework

W. Soule & Company USA

 Spool Fabrication - Automatic Welding with Pipe Rolling
Pipework

W. Soule & Company USA

 Welding Positioner / Turntable
Pipework

Anyeke.com.my
 Spool Fabrication Steps
Pipework

NDT
Cut Non Destructive
Testing

Bevel PWHT
Post Weld Heat
Treatment

Fit-up Blasting

Weld Painting
 Cable Laying
Pipework

Brief Description

132 kVa Cable laying .

 Cable Laying
Pipework
 Cable Laying
Pipework
 Cable Laying
Pipework
 Cable Laying
ⓒ David H Moloney
Miscellaneous

Cable Drum Stand Cable pulled on rollers

Cable Winch

Cable Drum Unloading Cable on rollers Cable Testing prior to Backfilling

 Transformers & Generators
Miscellaneous
 Generator & Primary Substation Building
Miscellaneous
Structural Steel & Miscellaneous
Structural Steel & Miscellaneous
 Airport Roof Truss
Structural Steel

Brief Description

Roof Truss 190 tonne in weight. Sections welded together on

trestles and the truss is lifted into position.

ⓒ David H Moloney
 Airport Roof Truss
Structural Steel

Roof Truss Sections Roof Truss Sections assembled on trestles

Trusses weigh 190 tonnes Crane Demag CC 8800

 Airport – Roof Section Mock-up
Structural Steel
 Airport Piers Roof Frames
Structural Steel

Sections assembled on trestles

 Pedestrian Boarding Bridges & Bridge House
Structural Steel
 Pedestrian Boarding Bridges & Bridge House
Structural Steel
 Pedestrian Boarding Bridges & Bridge Houses
Structural Steel

Mock-up
 Airport Roof Truss
Structural Steel
 Airport Roof Truss
Structural Steel
 Piers Construction
Structural Steel
 Piers Construction
Structural Steel
 Roof Covering
Structural Steel

Brief Description

Sequence is
Fix bottom sheet
Fix Vapour barrier
Fix Top Hat section and clips
Fit Insulation
Fix top sheet

ⓒ David H Moloney
 Roof Covering
Structural Steel

ⓒ David H Moloney
 Roof Covering
Structural Steel

ⓒ David H Moloney
 Roof Covering
Structural Steel

ⓒ David H Moloney
 View from ATC Tower
Miscellaneous
 View from ATC Tower
Miscellaneous
 View from ATC Tower
Miscellaneous
 Steel Building Multi-storey
Structural Steel

Brief Description

Sequence to erect a structural steel multi storey

building.

ⓒ David H Moloney
 Steel Building Multi-storey
Structural Steel

ⓒ David H Moloney
 Structural Steel Building Multi Storey
Structural Steel

Step 1 Set-out Grid Lines Step 2 Holding Down Bolts Step 3 Erect 1st level use core for stability

Step 4 Complete 1st Level Step 5 Erect following Levels Step 6 Plumb & Align Structure

3D images to show Construction Sequence. ⓒ David H Moloney

 Steel Building Single Storey
Structural Steel

Brief Description

Sequence to erect a structural

steel single storey portal building.

ⓒ David H Moloney
 Steel Building Single Storey
Structural Steel

ⓒ David H Moloney
 Structural Steel Building Single Storey
3D images to show Construction Sequence.
Structural Steel

Step 1 Set-out Grid Lines Step 2 Holding Down Bolts Step 3 Erect 1st Bay

Step 4 Erect 2nd Bay Step 5 Erect following Bays

ⓒ David H Moloney
 Airport Fuel Farm
Structural Steel

ⓒ David H Moloney
 Steel Storage Tank
Structural Steel

Brief Description

Sequence and methods to construct a

steel circular tank.

ⓒ David H Moloney
 Steel Storage Tank
Structural Steel

ⓒ David H Moloney
 Steel Circular Storage Tank – Construction ⓒ David H Moloney
Structural Steel
Structural Steel
Fireproofing Steel

Brief Description

Wet Mix Spray-Applied Fire Resistive Gypsum- based

Material to underside of roof deck – Site Trial
 Fireproofing Steel Deck Trial
Structural Steel
Piling
Piling
Piling Construction - Plant & Methods

Brief Description

Piling Plant, Equipment and Material;

Crawler Crane, Piling Hammer, Temporary Casing,
Piling Rig, Concrete Pump, Concrete Mixer Trucks,
Tremie Pipe and Reinforcement Cage
Piling
Piling Construction - Plant, Methods & Sequence
Piling
Piling Construction - Plant & Methods
Piling
Piling Construction - Vertical Piles
Piling
Piling Construction - Raking Piles
Piling
Piling Construction - Raking Piles
 Pile Load Test
Piling

Brief Description

A jack is used to load the pile in steps and

gauges measure any settlement.

ⓒ David H Moloney
 Pile Load Test
Piling

ⓒ David H Moloney
Roads & Pavings
 Asphalt Batching Yard
Roads & Pavings

Brief Description

Asphalt Batching Yard

Capacity of main batching plant is
250 tonnes per hour .
 Asphalt Batching Yard
Roads & Pavings
 Asphalt Batching Yard
Roads & Pavings
 Asphalt Batching Yard
Roads & Pavings
 Asphalt Batching Yard
Roads & Pavings
 Asphalt Batching Yard
Roads & Pavings
 Road Construction
Roads & Pavings

Brief Description

Sequence, methods and plant to construct a

motorway on a high embankment
 Road Construction
Roads & Pavings
 Road Construction
Roads & Pavings
 Runway Asphalt Pavement
Roads & Pavings

Brief Description

Sequence, plant and methods to construct a runway

 Runway Asphalt Pavement
Roads & Pavings
 Runway Asphalt Pavement
Roads & Pavings
 Runway Asphalt Pavement
Roads & Pavings
 Runway Asphalt Pavement
Roads & Pavings
 Runway Asphalt Pavement - Tests
Roads & Pavings
 Asphalt Pavement - 4 Pavers in Echelon
Roads & Pavings

Brief Description

4 pavers used to minimise lengths of cold joints

 Asphalt Pavement - 4 Pavers in Echelon
Roads & Pavings
 Concrete Slipform Paving
Roads & Pavings

Brief Description

Slipform Airport Concrete paving.

Texturing
& Curing

Spreader
Slipform Concrete Paver
 Concrete Slipform Paving – Texturing Machine
Roads & Pavings
 Concrete Slipform Paving - Slipform Machine
Roads & Pavings
 Concrete Slipform Paving – Placer / Spreader Machine
Roads & Pavings
 Concrete Slipform Paving
Roads & Pavings
 Concrete Slipform Paving
Roads & Pavings
 Concrete Slipform Paving
Roads & Pavings
 Concrete Slipform Paving – Drilling holes for dowels
Roads & Pavings
 Concrete Slipform Paving – Drilling holes for dowels
Roads & Pavings
 Runway Concrete Pavement
Roads & Pavings
 Runway Concrete Pavement - Tests
Roads & Pavings
 Runway Pavement - Marking
Roads & Pavings
Rail
Rail Underground

Twin Tunnels single track with

Cross passages at 250m intervals
for emergency evacuation

Tunnels in rock to avoid ground &

building settlement.
Depth 25 metres on average
ⓒ David H Moloney
 Rail Underground
Concrete
Rail Surface

Install Traffic Control Fencing & Welfare Facilities Divert Underground Utilities Excavate

Prepare Formation Reinforcement & Rails Reinforcement & Rails Paving

ⓒ David H Moloney
Paving Information Sign Trams in Operation Trams in Operation
 Rail Viaduct
Concrete

Brief Description

Shown is the construction of a light rail viaduct where

an overhead gantry was used to lift and place the
precast concrete viaduct segments.
 Rail Viaduct
Concrete
 Rail Viaduct
Concrete
Tunnels
 Micro Tunnelling
Tunnels

Brief Description

Micro tunnelling is used to dig small tunnels

where a tunnelling boring machine is
controlled from a cabin at ground level
 Micro Tunnelling
Tunnels
 Micro Tunnelling Sequence David H Moloney
Tunnels

ⓒ David H Moloney
 Pipe-jacking
Pipework

Brief Description

Method for pipe-jacking

The pipes are assembled in the access

shaft and are pushed using a hydraulic
jack..
 Pipe-jacking
Pipework
 Horizontal Directional Drilling
Pipework

Brief Description

Horizontal Directional Drilling under a taxiway.

Process
1. A pilot hole id drilled to the designed profile
2. A reamer is pulled back through the hole to enlarge it
3. A pipe string is pulled into the hole.
 Horizontal Directional Drilling
Pipework
Miscellaneous Works
 Fencing
Miscellaneous

Brief Description

Fencing.
Sequence of construction;
1. Clear and grade the ground.
2. Fix corner and straining posts.
3. Fix intermediate posts.
4. Fix line wire, chain-link and razor wire.
5. Construct concrete ground beam
Miscellaneous
Fencing
Miscellaneous
Fencing
Miscellaneous
Fencing
Miscellaneous
Fencing
 Cranes Lift
Miscellaneous

Brief Description

Lifting a large column / vessel from the horizontal and

rotate into the vertical using two cranes.
Miscellaneous
Cranes Lift
 Erect Flares / Columns & Vessels - 3D Simulation
Miscellaneous

Gas Processing Facility

 Airplane Wingtip Clearance
Miscellaneous

Brief Description

Regulation distances shown

for wingtip clearance.
 Airplane Wingtip Clearance
Miscellaneous
 Taxiway Reconstruction Airside
Miscellaneous

Brief Description

Regulations regarding working adjacent to

a live runway.
 Taxiway Reconstruction Airside
Miscellaneous
 Taxiway Reconstruction Airside
Miscellaneous
 Airfield Ground Lights Ducts & Chambers
Miscellaneous
 Airfield Ground Lights Ducts & Chambers
Miscellaneous
 Airfield Ground Lights Excavate Trench in CABC
Miscellaneous
 Airfield Ground Lights – Concrete Ducts
Miscellaneous
 Airfield Ground Lights
Miscellaneous
 Airfield Ground Lights
Miscellaneous

Jig to Level Pot

 Airfield Ground Lights - Core drill for Light
Miscellaneous
 Airfield Ground Lights Fit Pot with Jig
Miscellaneous
 Airfield Ground Lights
Miscellaneous
 ILS Localiser Antenna & Approach Lights
Miscellaneous
 Approach Lights
Miscellaneous
 Approach Lights
Miscellaneous
 ILS Glide Path Antenna
Miscellaneous
 DVOR Ground Station
Miscellaneous
 Airfield Ground Lights - Substation
Miscellaneous
Progress Monitoring & Administration
Progress Monitoring & Reporting - Dashboard
Brief Description
Dashboard is a single page, graphical representation of current progress and historical trends

ⓒ David H Moloney
Histogram Charts for Resources & Outputs

Brief Description

Histograms shows resources etc. for each month of a project.

Concrete per Location

Quantity for each month of the Project
Manpower per Discipline

Man-hours for each month of the Project

ⓒ David H Moloney
Plant & Equipment List & Worker’s Job Titles
ⓒ David H Moloney
Daily Work Record

Brief Description

Daily Work Records showing the

allocation of resources, materials and
work activities carried out daily.
Organogram

Brief Description

Shown are the line and

lateral relationships
between the various team
members and their relative
position in the site
organisation.
Staff Directory

Brief Description

List of staff and their

contact details
 Legend
Time Chainage Diagram
Brief Description

The chart has two axis: one for time and the other for location
A legend explains meaning of the colours, symbols and line types
Site Safety Posters examples
Filing System
Group Photos
Production by David H Moloney

My YouTube Channel link: https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ