Blue Grass Airport

Blue Grass Airport

Runway 4/22 Pavement Rehabilitation

Project Value: $3.2M

Project Engineer: HDR

Details: Runway 4/22 is LEX’s only commercial capable runway which results in unique maintenance and construction demands. In 2021, 4/22 was due an asphalt rehabilitation and AFC was chosen as the subcontractor to perform the associated electrical work. With the exception of the milling and paving which occurred over a three-day closure, all other work must occur only from 12am – 5 am with 4/22 reopening daily. With this requirement, all daily work must commence and be completed within 5 hours – including excavation and concrete pouring of new signs and NAVAID foundation.

Since a sizeable portion of 4/22’s traffic is commercial, the reopening safety standards were strict and non-negotiable and site conditions must be in full compliance. The first phase of this project was removing the top can sections of the in pavement fixtures and backfilling with quick setting concrete which we achieved using a custom, homemade device to avoid coring. During Phase 2, LEX was fully closed for three days from 6pm Thursday to 6pm Sunday to allow milling and paving operations for the entirety of Runway 4-22. For AFC, this phase required us to convert all Runway Edge and Threshold fixtures to the new LED fixtures by reopening Sunday evening.. Once the Phase 2 work was completed, the last phase of the project was the reinstallation of TDZ and Runway Centerline Fixtures via coring with new top can sections custom measured and ordered. AFC is grateful to ATS Construction, Blue Grass Airport, and HDR for their partnership, workmanship, and professionalism.

Project Highlights: 

  • 180 Touch Down Zone, 137 Runway Centerline, and 8 Runway Threshold light installed via two process method described above as well as converted to new LED fixtures
  • 83 LED Runway Edge and Threshold Lights
  • 139 LED Taxiway Edge Lights
  • 34 Runway and Taxiway Guidance Signs with new foundations
  • Over 90,000’ of #8 5kV Cable
  • New MALSR towers and foundations for the first three stations due to a new EMAS installation
  • New FAA 4-2’’ duct and manhole system for new MALSR foundations
  • Two new RPU’s with 5 surface sensors and associated cable
  • Two new L849(L) REILs
  • Three new Constant Current Regulators and ALCMS upgrades

AFC has countless other projects ranging from $15,000 to $2M in our portfolio at various airports in Kentucky, Tennessee, Virginia, Indiana, and Ohio with references available upon request.

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