SPECIAL REPORT
Key Issues to Consider When Choosing Mobile Concrete Production Plants for Airport Runway and Maintenance Key Issues to Consider When Choosing Mobile Concrete Production Plants for Airport Runway and Maintenance Why Now is the Time to Look at Runway Surfaces Going Mobile: How Airports are Embracing the Mobile Cement Plant Cement Mixing Plants: The Benefits of Mobility Mobile Cement Mixing Can Help Meet the Carbon Challenge
Published by Global Business Media
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KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
SPECIAL REPORT
Key Issues to Consider When Choosing Mobile Concrete Production Plants for Airport Runway and Maintenance Key Issues to Consider When Choosing Mobile Concrete Production Plants for Airport Runway and Maintenance
Contents
Why Now is the Time to Look at Runway Surfaces Going Mobile: How Airports are Embracing the Mobile Cement Plant Cement Mixing Plants: The Benefits of Mobility Mobile Cement Mixing Can Help Meet the Carbon Challenge
Foreword
2
Tom Cropper, Editor
Key Issues to Consider When Choosing Mobile Concrete Production Plants for Airport Runway and Maintenance
3
Cemen Tech Inc. Published by Global Business Media
Implications of Airport Runway Maintenance
Published by Global Business Media
Volumetric Concrete Mixing
Global Business Media Limited 62 The Street Ashtead Surrey KT21 1AT United Kingdom
Why Now is the Time to Look at Runway Surfaces
Switchboard: +44 (0)1737 850 939 Fax: +44 (0)1737 851 952 Email: info@globalbusinessmedia.org Website: www.globalbusinessmedia.org Publisher Kevin Bell Business Development Director Marie-Anne Brooks Editor Tom Cropper
Conclusion
Tom Cropper, Editor
Impact of Downtime Opportunity Knocks
Going Mobile: How Airports are 9 Embracing the Mobile Cement Plant Rethinking Surfaces Mobile Cement Mixers
Advertising Executives Michael McCarthy Abigail Coombes
Cement Mixing Plants: The Benefits of Mobility
For further information visit: www.globalbusinessmedia.org The opinions and views expressed in the editorial content in this publication are those of the authors alone and do not necessarily represent the views of any organisation with which they may be associated. Material in advertisements and promotional features may be considered to represent the views of the advertisers and promoters. The views and opinions expressed in this publication do not necessarily express the views of the Publishers or the Editor. While every care has been taken in the preparation of this publication, neither the Publishers nor the Editor are responsible for such opinions and views or for any inaccuracies in the articles.
James Butler, Staff Writer
Senior Project Manager Steve Banks
Production Manager Paul Davies
7
11
Jo Roth, Staff Writer
Speed and Efficiency Cost and Waste Operating Conditions Flexibility Technology
Mobile Cement Mixing Can 13 Help Meet the Carbon Challenge Tom Cropper, Editor
Ambitious Targets Going Beyond Paris How Mobile Concrete Mixing Can Help
References 15 Š 2020. The entire contents of this publication are protected by copyright. Full details are available from the Publishers. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical photocopying, recording or otherwise, without the prior permission of the copyright owner. WWW.AIRPORTTECHNOLOGYREPORTS.COM | 1
KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
Foreword R
unway surfaces are one of the most crucial
New concrete mixes can be harder wearing and
parts of a functioning airport. How they
quicker setting, allowing engineers to complete
perform, how quickly they can be laid and how
resurfacing projects in a timelier manner. However,
long they last without maintenance will be key
due to their characteristics, they often require a
factors in whether an airport can meet the financial,
different approach to mixing, which allows them to
environmental and logistical pressures coming their
be batched and mixed on the spot.
way over the coming years.
As Jo Roth goes on to explain, mobile cement plants
Our first article comes from leading provider of
can open up the use of new surfacing technologies as
cement solutions CemenTech. They provide an
well as offering a host of benefits to airports, including
excellent overview of how surfacing technology has
faster turnaround times and lower waste. All these will
evolved over the years and the new technologies
be crucial in helping airports maintain sustainable
coming to the fore.
operations now and into the future.
These processes and technologies will be vital
Finally, we look at one of the issues which will
as the aviation sector struggles to cope with
become increasingly important for the future of
an increasingly challenging environment with the
aviation: the environment. The climate emergency has
fallout from COVID 19. Our second article goes
come to the fore in the last few years and the aviation
into these challenges in more detail. While the
sector, like other industries, has committed itself to
pandemic has had a major impact on revenues
ambitious carbon reduction targets. These will have
and created anxiety throughout the industry, the
to be achieved while also dramatically increasing
lockdown does create an opportunity to schedule
capacity. It will be one of the biggest commercial and
maintenance at a time when traffic is reduced.
environmental challenges confronting any sector and,
James Butler then turns his attention to
to meet it, airports will have to be innovative.
developments in runway surface technologies
Mobile cement plants help operators meet all these
and why these are contributing to the need for
challenges. They can be faster, use fewer materials
mobile solutions. Although the aviation sector
and reduce carbon use. For a sector which faces
has evolved dramatically over the decades, surface
environmental, logistical and financial challenges,
composition is still based on methodologies
thist will be increasingly important for the future.
dating back decades. With aircraft becoming heavier and traffic busier, surfaces are coming under strain.
Tom Cropper Editor
Tom Cropper has produced articles and reports on various aspects of global business over the past 15 years. He has also worked as a copywriter for some of the largest corporations in the world, including ANZ Bank, ING and KPMG.
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KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
Key Issues to Consider When Choosing Mobile Concrete Production Plants for Airport Runway and Maintenance Cemen Tech Inc.
The flexibility of mobile concrete production lends itself to airport infrastructure and runway repairs
F
OR ANY airport, an out-of-service runway is not an option. In 2018, HartsfieldJackson Atlanta International Airport saw 107.4 million airline passengers, the most of all airports around the worlda. With the global average growth rate in airline travel projected at 4.1 percent from 2017 to 2040, it will become more imperative for fast and effective runway installations and repairs.b A 2003 report by the U.S. Government Accountability Office recommended new runway planning begin when an airport reaches 60 percent to 75 percent total annual flight capacity. While the recommendations focus on the U.S., many airports globally continue to see an increase in passenger and traffic volume which will increase their annual flight capacity.c The flexibility of mobile concrete production lends itself to airport infrastructure and runway
repairs. Each unit is pre-loaded with necessary aggregates, admixtures, and other materials and driven to the job site, reducing the amount of time and carbon emission generally associated with traditional batch plants. They allow entities, such as airports, to pour concrete when it is needed, which contributes to keeping a runway project on track.
Implications of Airport Runway Maintenance Runway Maintenance Overview Generally, runway maintenance is the regular rehabilitation of the top surface layer, which wears with natural exposure and use over time.d How often a runway needs maintenance is frequently dictated by the type of surface. Many major commercial airports use concrete as the surface provides more durability and longer WWW.AIRPORTTECHNOLOGYREPORTS.COM | 3
KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
Because the hydration process begins once the water, cement, and aggregates converge, it is essential to avoid mixing until crews are ready for concrete placement
functional lifespan than asphalt.e Commonly, dowels and rebar provide structural support for the sections, which may reach depths of 16 inches to 21 inches each. Because water creates a skid hazard for any aircraft, concrete runways feature grooves to allow drainage instead of pooling. The overall goal is to provide a landing surface with an appropriate amount of friction at all times. Macrotexture The visible roughness of a runway – this texture allows water to escape, or drain, from underneath the aircraft’s tires.f Its importance increases alongside any development of aquaplaning factors. Microtexture A fine-scale roughness - it is the small, individual aggregate particles detectable through touch. It is primarily important at low speeds as it allows the tire to break through the residual water film and gain traction on the runway. Impact of Scheduled and Unscheduled Maintenance Paris-Orly Airport replaces one concrete slab per night to reduce disruption and to ensure runway has a complete overhaul every other year.g Despite the time and planning this proactive approach requires, it reduces the need for and
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impact of unscheduled maintenance should a runway display symptoms of failure. This is crucial, as the airport saw a 3.4 percent increase in passengers in 2018 with more than 33.1 million people flying to or through Paris-Orly.h Financial Implications While scheduled maintenance is what every airport strives for, situations arise where financial incentives may be necessary for project completion. When this occurs, the incentives may or may not impact the project budget, depending on whether it was planned for from the onset. Impact on Air Travel Emirates Airline announced in early 2019 the scheduled maintenance and subsequent closure of Dubai International Airport’s southern runway.i A major airport for international travelers, it was reduced to one runway during a six-week period. This resulted in the cancellation and/or retimed flights and other changes in operating aircraft. Since Emirates Airline served more than 58 million passengers in 2018, the impact of the runway closures likely caused numerous last-minute adjustments to travel plans for many passengers.
Volumetric Concrete Mixing Fast Setting Formally called belitic calcium sulfoaluminate (BCSA) cement, concrete made with this type of
KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
cement can be ready for traffic or other use within three to four hours. Although the cost of BCSA is a common concern – it is usually double the cost of Portland cement – the ability to reopen a runway in a short amount of time, therefore reducing the stresses on airport operations, mitigates this. Moreover, because the hydration process begins once the water, cement, and aggregates converge, it is essential to avoid mixing until crews are ready for concrete placement. Mobile concrete mixers are ideal when using fast setting concrete due to the material’s rapid set-up time. Once mixed and subsequently poured, the concrete begins to set up within 30 minutes, decreasing the amount of downtime for a finishing crew. Use of fast-setting concrete is extremely difficult, if not impossible, with a traditional barrel mixer. This is due to the immediate start of the hydration process, leaving a drastically reduced time frame to pour and place the concrete. If the mixer is delayed for any reason, or the finishing crew is not ready upon the mixer’s arrival, then the concrete may be deemed insufficient, wasting the load. Fiber Reinforced Fiber-reinforced concrete has become a popular alternative to placing rebar or wire mesh in the form before pouring. The type of fiber added to the admixture varies based on the project but may include glass, natural, steel, and/or synthetic. It has been used in concrete work at numerous airports and airfields, including Norfolk Naval Air Station, John F. Kennedy International Airport, Chicago O’Hare International Airport, and London Heathrow Airport.j High Slump This kind is often found in applications where high final strength is necessary for structural integrity, such as bridges and parking structures. Using
a mobile concrete mixer in this type of setting allows for minimal work stoppage thus reducing traffic delays. Pumped A concrete pump is frequently used when access and/or space limitations hamper a project. Because the mix is poured from the mixer directly into the pump, adequate viscosity is crucial. But using a volumetric concrete mixer gives you full control over the exact amount of water added and when. This not only improves the final quality of the concrete but diminishes the likelihood of a clogged pump. Custom Concrete for Each Project Because the needs and use of a runway vary by airport and geographic region, each one must be built with those specifics in mind. Volumetric concrete mixers are designed and built with separate material storage and certain models can store pre-programmed mix designs. This allows for truly custom concrete for each runway repair and installation and the assurance the poured concrete is exactly what the project needs.
While scheduled maintenance is what every airport strives for,
Conclusion Formally announced by ACI Europe in June 2019, 194 airports in 24 European countries pledged to become net-zero for carbon emissions by 2050.k As air travel is projected to continue growing, airports and entities which oversee their maintenance and operations want means to keep this pledge. Mobile concrete production is one area which can help keep them on track through precise measuring and mixing. This translates to decreased carbon emissions as the equipment is driven to the job site before concrete production begins and less water usage during the process. Many mixers have the capability for technology and software integrations which can further
situations arise where financial incentives may be necessary for project completion
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KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
However seemingly small, these details can help a concrete producer and airport further refine their concrete needs and plan for future repairs and installations
pinpoint inefficient areas, such as mixer runtime and aggregate usage. However seemingly small, these details can help a concrete producer and airport further refine their concrete needs and plan for future repairs and installations. Furthermore, using volumetric mixers puts airports in control of how, when, and where needed concrete is mixed. This expedites airfield and runway repairs which, in turn, assuages scheduling conflicts and travel delays sooner for passengers. Additionally, costs related to the concrete decline as overage charges, short load, and disposal fees are eliminated because of the precision involved throughout. Labor and staffing expenses also decrease as fewer people are needed to complete each job – volumetric mixer drivers are called operators as they drive and operate the unit. Having a volumetric mixer in the fleet of equipment means having the ability to pour concrete on schedule without the hassle and delays often associated with traditional barrel
CONCRETE AIRPORT RUNWAY DIRECTIONAL LINES
mixers. Many concrete producers who work with airports and related entities either use or are beginning to use volumetric mixers in their operations. This shift in concrete production provides many short- and long-term benefits to everyone involved in and benefiting from airport infrastructure repairs.
References: a
https://www.cnn.com/travel/article/worlds-busiest-airports-2018-preliminary/index.html
b
https://aci.aero/wp-content/uploads/2018/11/WATR_WATF_Infographic_Web.pdf
c
https://www.gao.gov/new.items/d03164.pdf
d
https://www.skybrary.aero/index.php/Runway_Maintenance
e
http://www.nycaviation.com/2015/01/built-last-runways-built/37734
f
https://www.skybrary.aero/index.php/Runway_Surface_Friction
g
https://bit.ly/3gamgTU
h
https://bit.ly/3f5WLBQ
i
https://bit.ly/2P4zNR0
j
https://intrans.iastate.edu/app/uploads/2019/04/FRC_overlays_tech_ovw_w_cvr.pdf
k
https://bit.ly/30zSxhQ
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KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
Why Now is the Time to Look at Runway Surfaces Tom Cropper, Editor Lockdown has created challenges on an unprecedented scale, but this slowdown could be an opportunity for airports to make important upgrades.
I
T’S FAIR to say 2020 has been tough. With countries across the world locking down, air travel has slowed to a trickle. Revenues have been decimated and aviation companies have been crying out for Government support. However, this unexpected period of downtime also creates an opportunity for airports to review all aspects of infrastructure, especially the surfaces of their tarmac.
Impact of Downtime In the normal run of events, airports are terrified of downtime. Any closure of a runway for scheduled or urgent maintenance will slow down operations and impact revenues. To minimize the harm done, airports will often develop incremental repair schedules such as replacing part of the runway surface during the night to avoid the need for a complete shutdown. New technologies and materials exist which can improve dramatically the performance of runways. However, the need to maintain operations holds airports back from investing in significant upgrades. With passenger numbers booming and capacity under strain, every hour, minute and second is crucial. A small delay in one function can have serious consequences across the entire airport. Coronavirus has changed everything. Passenger numbers have plummeted around the world. In China, one of the hotspots of international growth, numbers fell by 85%1. In Europe, airports reported falls in passenger numbers of almost 100%. In May, only 4.3 million people travelled through European airports compared to 2019’s figure of more than 200 million2. Surging growth and strained capacity have been replaced by uncertainty. The impact has been devastating. At a shot, the aviation industry’s revenue has been virtually shut off as Olivier Jancovec, of ACI Europe says. “With well over half a billion passengers lost so far this year, and still no revenues coming in, Europe’s airports are anxiously waiting for travel restrictions to be lifted and airlines to resume operations.”
In March 2020, IATA predicted the aviation industry could lose between $63 and $113bn in revenue. However, Jancovec issued a note of hope. “With the epidemic now de-escalating in many countries and a plan to allow for intra-European travel – at least within the Schengen area – by the end of the month,” he said, “we are finally seeing some light at the end of the tunnel.” The impact on air passenger numbers has indeed been profound. Pre lockdown predictions of a doubling in air passenger numbers over the next 20 years now appear fanciful. However, an event such as this should not have been entirely unexpected. Over the decades, future predictions have frequently been confounded by unexpected or black swan events, which hold back the seemingly unstoppable march of progress such as 9/11 or the 2008 financial crisis. These may be unforeseen, but over a prolonged period of time, events such as these are to be expected. Indeed, a look back at history suggests these events tend to happen about once a decade. In short, COVID 19 may have provoked a dramatic drop in air travel, but long-term trends remain the same. The thirst for air travel remains and it may have even been stoked by the enforced lockdown. Once restrictions are lifted and life returns to normal, airports will be bursting at the seams once again. The challenge, for airports, therefore, comes in several layers. In the immediate term they have to cope with the sudden impact on their revenues. Governments have been swift to help by pumping billions of pounds in rescue packages into the industry. In the short to medium term, they will have to manage with the recovery as the world gets back on its feet again. But in the longer term, once again they will be facing the same capacity challenges. With all these challenges, efficiency will be key. Airports will need to optimize operations, minimize costs and maximize revenue opportunities.
In short, COVID 19 may have provoked a dramatic drop in air travel, but long-term trends remain the same. The thirst for air travel remains and it may have even been stoked by the enforced lockdown
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KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
With passenger numbers depressed, the cost of downtime is lower, and it is possible to schedule sizeable renewal operations without a serious impact on day-to-day operations. One of the most important factors will be the concrete used in surfacing tarmac
VOLUMETRIC CONCRETE CAN BE PUT INTO TEST CYLINDERS WITHIN MINUTES OF POURING
Efficient operations and robust infrastructure will be crucial, which is why this period should be seen as an opportunity.
Opportunity Knocks With passenger numbers depressed, the cost of downtime is lower, and it is possible to schedule sizeable renewal operations without a serious impact on day-to-day operations. One of the most important factors will be the concrete used in surfacing tarmac. Renewing runway surface can potentially reduce the need for maintenance, improving grip and making operations more sustainable. New technologies and mixes are being developed which offer major performance gains to help airports meet their key performance indicators such as time, turnaround and carbon use. Each of these will require an investment of time and money. However, they will deliver a significant return on investment in terms of faster setting, quicker reopening, reduced maintenance and improved safety. Meanwhile, new equipment such as mobile cement mixers enable airports to more precisely
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measure the amount of material used, reducing the cost of operations and improving their sustainability. They also enable them to use the latest ultra-fast setting concrete mixes which enable them to cut dramatically the time needed to reopen a runway and get traffic moving again. At a most basic level, though, this is an opportunity to exit lockdown and enjoy the easing of restrictions with runway surfaces in the best possible condition, and to schedule large scale maintenance at a time when it will have a minimal impact on operations. It’s like a Formula 1 team stopping their car under a safety car. With everything slowing down they understand they have an opportunity to replace tires while reducing the amount of time lost, and to be in the best possible condition once racing resumes in earnest. In the same way, those airports which will be successful over the coming years, once restrictions have been restricted, will be those who have used this time well and put themselves in the best possible position to cope with the influx of traffic once activity is back up to full speed.
KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
Going Mobile: How Airports are Embracing the Mobile Cement Plant James Butler, Staff Writer Airport surfaces need to be tougher, more durable and faster to lay, which is why mobile units that can batch and mix concrete on the spot offer important advantages.
F
OR DECADES, airport runways have relied on a similar approach to laying cement. In the first instance, a batch is produced and then transported to the works location. However, several factors are combining to encourage a move to mobile cement plants which mix the cement there and then on the spot. With operators now working on increasingly fine margins, the time is right for many airports to go mobile. Runway surfaces are one of the most important features of an airport.They have to ensure the safe arrival and departure of aircraft and handle an increasing volume of traffic. With the strain placed on tarmac increasing every year, keeping it in top condition is crucial. At the same time, airports operate in an environment in which every penny and every second is critical. To meet these challenges, operators will have to be innovative and embrace the latest technology available.
Rethinking Surfaces Today’s runways come under strain from all angles. Aircraft are becoming heavier and flights more frequent. Regulations are strict. The ICAO’s Annex 14 document3 requires asphalt surfaces to: • be constructed and maintained without deviations of bumps which would affect aircraft operations. It must be resistant to shearing and rutting to remain smooth and free draining; • have good friction characteristics when the surface is wet; • be maintained free of loose material on the surface to prevent damage to the aircraft. In practice, this requires airport asphalt to be durable and resistant. Some of these regulations are contradictory. It is possible, for example, to construct a highly deformation resistant mixture with coarsely graded asphalt, but such a mixture is unlikely to be durable. Accordingly, any surface mixture will always have to be a balance of these
requirements to produce something which meets the demands of the regulator. Equally, each surface will require a regular schedule of maintenance and measurement to ensure it remains compliant. Any surface which requires high levels of maintenance and regular repair will increase the costs of daily operations and eat into the financial sustainability of the operation. Today, this is becoming increasingly serious thanks to the greater demands being placed on surfaces. The methods used in the construction of runway surfaces still often trace their origins back to the 1940s and 50s. As such, most runway surfaces are constructed from asphalt surfaces which are 40 to 60mm, densely graded with grooves sawn across them to promote skid resistance. However, as a paper in ScienceDirect shows,4 aircraft have become much heavier and more demanding on runway surfaces. The report suggests that, as a result, traditional airport asphalt specification has failed to guarantee good aircraft surface performance. To counter this issue, airports have been looking at alternative asphalt mixes with fresh approaches and equipment taking the modern airport away from the traditional approach to surfacing. For example, in the 70s and 80s, airports such as Norfolk Naval Air Station, Fallon Naval Air Station as well as commercial airports (Newark International Airport, John F. Kennedy International Airport, and Tampa International Airport) started to use fiber reinforced concrete5. According to a report from the National Concrete Pavement Technology Centre, “A 20-year survey of the post-tensioned FRC section (1,200 ft in length) and FRC-only sections with transverse joint spacing varying between 85 and 200 ft demonstrated that the taxiway is experiencing excellent performance.”
Runway surfaces are one of the most important features of an airport. They have to ensure the safe arrival and departure of aircraft and handle an increasing volume of traffic
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KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
A VOLUMETRIC MIXER POURS CONCRETE INTO A BUCKET FOR A BRIDGE PIER PROJECT.
Mobile plants such as these work faster and are more flexible than most conventional cement mixers. They give operators the option of using any type of design or mix in any environment. They can adjust designs or move location at short notice, and reduce waste and downtime
Faster setting mixes, meanwhile, such as belitic calcium sulfoaluminate (BCSA) cement, can be ready for use within three to four hours. Although double the cost of conventional Portland cement, it drives down the time required before a runway can be open for traffic again as well as improving the durability of the surface. It has also been used in low carbon footprint mortars and presents an option for airports looking to meet their carbon goals. However, there are concerns about the hydration process6, which starts immediately and can reduce the available time to pour and place the concrete.
Mobile Cement Mixers This lower time limit is one reason why mobile concrete plants are becoming more popular. CemenTech, for example, focus on what they describe as Volumetric mixing, which involves a batch plant and mixer in a single unit. These mobile mixers can be driven to the site and can batch, measure and mix the concrete from one unit. This is faster, requires less down time and allows fresh concrete to be poured wherever it is needed. Mixes can be adjusted as and when required and can be tailored to a precise design and mix7. Mobile plants such as these work faster and are more flexible than most conventional cement mixers. They give operators the option of using any type of design or mix in any environment. They can adjust designs or move location at
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short notice, and reduce waste and downtime. Teams can deliver precise amounts of mix in the exact location without the delay of waiting for a mix to be brought to their location. Volumetric mixing also helps teams perform faster repairs in more remote locations and harsher environments. An extreme example of this could be seen in 2016 when a team of US engineers arrived at Qayyarah Airfield, 40 miles outside Mosul in Iraq. After two years of occupation by ISIS, the runway had been damaged seemingly beyond repair. However, in a project which had never been attempted within Iraq, the team managed to clear an area the size of 33 football pitches laid end over end and, using ADRs rapid repair mixers from CemenTech, laid down more than two million pounds of concrete on a runway of slightly more than a mile. The runway was inspected and certified and Qayyarah Airfield was quickly open for business once more8. With the demands of surfacing becoming more complicated, mobile batch and mixing plants offer substantial performance, cost and efficiency gains to airports. They help them to work faster, to be more flexible and more sustainable. It’s a solution which can help airports produce more durable, high performance surfaces which reduce the cost of maintenance and downtime. In an environment in which small gains are crucial, ‘volumetric’ surfacing is increasingly appealing.
KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
Cement Mixing Plants: The Benefits of Mobility Jo Roth, Staff Writer Faster, more mobile and more flexible. Mobile cement mixing plants offer a number of advantages over conventional approaches.
I
N LIFE, as in business, the future is mobile. Everywhere you look, technology is becoming smaller, lighter, more portable and more powerful. The benefits for its users are enormous. The same trends are being seen when it comes to construction. Mobile concrete plants which can batch and mix concrete on the spot offer enormous improvements to any project. However, when making the decision about whether to upgrade, operators will need to understand how they will see a return on investment. In this article, we’ll examine the key issues operators will be looking at.
Speed and Efficiency When time is critical, mobile plants can save precious minutes at several points in the process. Ready mix concrete can hold up operations as a result of the wait for the mix to arrive. In comparison, mobile units can mix the cement there and then. Concrete can be mixed and laid within 30 minutes while fresh. Productivity increases, delays are reduced, and jobs can be completed sooner. Mobile units are also more suitable to ultrafast drying types of concrete. Because the hydration process starts immediately, they can be difficult to use with a conventional barrel mixer. At best, the risks of spoilage are higher; at worst it could be impossible to use. Mobile mixers allow workers to mix and pour the cement right at the point of work, with no risk of a delay in transportation.
Cost and Waste Financial and environmental considerations mean operators need to become extremely sensitive to their use of materials. At the best of times, airport finances are a fine balancing act – even more following the arrival of COVID 19. According to analysis from ACI World, COVID 19 could see airport revenues fall by half9. Such a financially constrained environment will put pressure on operations to become more efficient and frugal. While faster drying concrete
and mobile plants will involve an upfront cost, operators should set that against the additional revenue it brings thanks to faster turnaround times and lower operating expenses. The aviation industry has adopted Paris Agreement targets of hitting net zero carbon emissions by 205010. However, many airports have chosen to go above and beyond this figure with some, such as Heathrow, aiming become carbon neutral by 203011. This is an enormous challenge. Between now and 2050, the aviation sector is set to expand dramatically and hopes to grow while achieving an unprecedented reduction in emissions. For this to happen, waste must be minimized at every opportunity. Mobile concrete plants represent one such opportunity. The current approach of transporting premixed concrete inevitably involves some excess as well as the risk of spoilage. A mobile plant, on the other hand, allows operators to produce the exact quantity of concrete at the exact time it is required. Computer control systems mean workers can achieve precise measures and eliminate waste. It is therefore faster, more economical, and environmentally sustainable. Ease of use will also have an impact on cost. Plants in which all operations can be performed by one person reduce head count and lead to a quicker and simpler form of operation.
Financial and environmental considerations mean operators need to become extremely sensitive to their use of materials. At the best of times, airport finances are a fine balancing act – even more following the arrival of COVID 19
Operating Conditions Due to the range of tasks and conditions a plant may face, it must be suitable for different challenges. On the one hand it will need to be light and mobile enough to move quickly to different locations, but on the other it must be strong enough to cope with any conditions. The environment of an airport can be tough and wide-ranging. Depending on the time of year or location of the airport, it may be required to operate in anything from 40-degree heat to subzero snowy conditions. Plants will also need the capacity to cope with high loads as well as being able to switch locations at short notice. WWW.AIRPORTTECHNOLOGYREPORTS.COM | 11
KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
VOLUMETRIC MIXERS ARE GREAT FOR WORK LOCATED IN REMOTE LOCATIONS AS CUSTOMERS RECEIVE FRESHLY MIXED CONCRETE ON-SITE.
The great advantage of a mobile concrete batch plant is that it offers unparalleled levels of flexibility. It can be set up easily, cope with varying loads and switch the design mix onsite when needed
Mobile units, therefore, will need to be light and flexible enough to move quickly between locations while also being sufficiently robust to cope with all the conditions they will face in day to day operations. Each project will come with its own specific set of challenges and risks. Providers who are flexible enough to work with buyers to provide them with the level of specification they require will offer significantly more value.
Flexibility The great advantage of a mobile concrete batch plant is that it offers unparalleled levels of flexibility. It can be set up easily, cope with varying loads and switch the design mix onsite when needed. The unit will need to be light and flexible enough to be able to move to any location on the airport at short notice, even if the site is remote or hard to get to. Once there, it should not be limited by space and be able to cope with a job of any size whether it’s laying 20 meters of surfacing or 400 meters. Fast cleanout keeps downtime to a minimum. The latest high-performance plants offer fast cleanout with swift separation of materials so that the plant can be ready to go again quickly.
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Technology Digital technology will also be crucial to future operations. Mobile plants can be fitted with software packages which provide precise information about production quantities and resource use. This produces valuable data which can be analyzed to provide insights on trends and material use. Using this information, operators will be able to track their costs and resource use more effectively and derive learnings for the future. In the airport of the future, data will be critical to operations, providing insights and analysis which can unlock previously hidden opportunities for efficiency and performance improvements. The more tasks and functions that can be linked to a central database, the easier it is for managers to gain oversight of their operations and drive the improvements necessary for the airport to thrive in the modern environment. The mixing of concrete may seem like a small task, but this is the very nature of aviation. It is a vast network of interconnected, small and seemingly trivial tasks. Small gains at each point in sustainability, speed, cost and efficiency can add up to a transformation in an operation’s overall performance. The ability to add mobility into concrete mixing plant has multiple benefits which help an organization become successful.
KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
Mobile Cement Mixing Can Help Meet the Carbon Challenge Tom Cropper, Editor Airports around the world are setting themselves the challenge to become net zero somewhere in the 2030s. Could mobile concrete mixers provide part of the answer?
T
HE AVIATION sector comes in for intense criticism for its carbon output, but it’s not always fair. While it is one of the most carbon intense industries in the world, the sector has worked harder than most to reduce its impact on the environment. While the Paris Climate Accords commit the world to becoming carbon neutral by 2050, many airports around the world are going a step further with some hoping to hit the target in the early 2030s.
Ambitious Targets At the UK’s largest airport, Heathrow, they have already reduced emissions from its operations by more than 90%. It’s the first international hub to become carbon neutral and the first to commit to achieving net zero carbon emissions by the mid-2030s. Its action plan ‘Target Net Zero’ aims to decarbonize operations, flights and help the industry meet its overall plan of net zero by 205012. Towards the end of 2019, Birmingham Airport also set itself a target of net zero by 2033. The airport’s CEO, Nick Burton, admitted that they did not yet have the answers about how this will be done, but they are currently working on an action plan which they hope will answer some of those questions. “We don’t have all the answers about how we will hit this target,” he said, “but we are confident that through innovation and collaboratively working with industry, government, manufacturers, on-site partners and employees, we can reach our target by 203313.”
Going Beyond Paris It’s difficult to overstate just how big a challenge this is. Airports such as Heathrow and Birmingham have decided to move more quickly than the Government and the wider aviation industry which have set their sights on hitting the target by 2050. However, they will be doing so against a backdrop
of a rapid growth in airport traffic and capacity. Although COVID 19 has slowed growth, the longterm picture remains the same. Millions of people are taking to the skies every year and capacity will need to increase in order to meet it. For an example of the uncertainty surrounding expansion plans we can take the Aviation Environment Federation’s analysis of Gatwick’s 2019 Master Plan for expansion14. This allows for opening its existing standby runway while also opening up land for building another. It hopes to grow passenger numbers to 70 million per annum by 2032/33, a 53% increase on the 45.7 million passengers who used the airport in 2017/1815. However, it is uncertain about its impact on the environment. The Masterplan estimates emissions will grow from 0.77MtCO2 in 2017 to 0.95MtCO2 in 2028, according to the Aviation Environment Federation. However, estimates from the Department of Transport which include more indirect emissions, suggest they may hit 2.7MtCO2 by 2050 in a scenario in which Heathrow opens a third runway and Gatwick’s standby runway remains unused16. The unavoidable conclusion is that it will be very difficult to expand capacity in the way airports want while meeting those targets. To do so, airports will have to look at every part of the process including the way in which cement is mixed and transported to the work site. Here, tremendous gains are to be had by moving beyond traditional methods of cement mixing towards something which is more mobile and efficient.
Although COVID 19 has slowed growth, the longterm picture remains the same. Millions of people are taking to the skies every year and capacity will need to increase in order to meet it
How Mobile Concrete Mixing Can Help Mobile concrete mixing is one way in which airports can achieve their emission reduction targets. It allows for more precise measuring WWW.AIRPORTTECHNOLOGYREPORTS.COM | 13
KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
AN AIRPLANE TAKES OFF IN THE DISTANCE AS A CREW REPAIRS A RUNWAY WITH A VOLUMETRIC MIXER.
Mobile concrete mixing is one way in which airports can achieve their emission reduction targets. It allows for more precise measuring and mixing of concrete and for all equipment to be driven to the job site before concrete mixing begins. This translates to less water usage and less waste
and mixing of concrete and for all equipment to be driven to the job site before concrete mixing begins. This translates to less water usage and less waste. The latest concrete mixers also incorporate software which provides enhanced real time data about cement use, generating insights which operators can use to drive further improvements. With this information, users can analyze data such as aggregate use and the run time of the mixer. This allows them to optimize the energy and material use for any situation. This will help to better plan forward schedules and the use of materials. Mobile mixers also open up the use of volumetric cement mixing. This is becoming more popular with operators as it allows for faster mixing, helps to get repairs done and open runways more quickly. However, this is very difficult for traditional cement mixers as any delay in transport to the work site can result in the mix being spoilt and unusable. Mobile mixers allow it to be taken directly to the work site, cutting down the risk of delay and waste.
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Upgrading to new work vehicles can also improve efficiency. Modern engines are substantially more efficient. However, many vehicles used to transport equipment around the airfield are a decade or more old. Moving to newer models may involve a capital outlay, but they will contribute towards carbon goals by using less fuel. Airports are moving to electrical and hybrid vehicles on the ground to further cut their carbon footprints. Technology, then, can be a crucial tool in the fight against climate change. It helps airports meet their twin, and sometimes contradictory, goals of increasing capacity while also reducing the use of carbon. Moving from static to mobile cement mixing processes may seem to be a small detail in the wider scheme of things, but to meet a challenge on this scale, such details will be immensely important. To reduce carbon output while increasing productivity, the aviation sector will need to transition equipment which can improve performance while using fewer resources. Mobile cement mixers are a vital part of that equation.
KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
References: Coronavirus: Huge Impact Revealed: https://www.independent.co.uk/news/world/asia/coronavirus-china-flight-airline-passenger-airport-travel-covid-19-a9396271.html
1
European Airports Report Almost 100% Fall in Passengers: https://www.internationalairportreview.com/news/118517/europe-airports-almost-100-per-cent-fall-passenger-numbers/
2
Annex 14: https://www.icao.int/APAC/Meetings/2016%20ICAOPIS/3%20ICAO%20Annex%2014%20Standards%20and%20Aerodrome%20Certification.pdf
3
4
State of the Art Asphalt: https://www.sciencedirect.com/science/article/pii/S1996681417300068
5
Fibre Reinforced Concrete for Pavement Overlays: https://intrans.iastate.edu/app/uploads/2019/04/FRC_overlays_tech_ovw_w_cvr.pdf
6
Calcium Sulfoaluminate Cement: Hydration chemistry, performance, and use in the United States: https://bit.ly/2CL1EDf
7
How Volumetric Mixing Works: https://cementech.com/most-popular-questions/how-volumetric-mixing-works/
8
Qayyarah West Airfield: https://cementech.com/video-center-2/
9
ACI World States COVID 19 Could Reduce Revenues by Half: https://www.airport-technology.com/news/aci-world-states-covid-19-could-reduce-airport-revenues-by-half/
British Aviation Industry Outlines Plans to Achieve net Zero by 2050: https://uk.reuters.com/article/uk-britain-aviation-emissions/british-aviation-industry-outlines-plans-for-net-zero-emissions-by-2050-idUKKBN1ZY00B
10
Heathrow Pledges to Become Carbon Neutral by 2030: http://www.climateaction.org/news/heathrow-pledges-to-become-zero-carbon-airport-by-2030
11
12
Heathrow Targets Net Zero: https://www.heathrow.com/latest-news/heathrow-targets-zero-carbon-airport-by-mid-2030s
Birmingham Airport Sets Itself a Net Zero Target for 2033: https://www.internationalairportreview.com/news/107003/birmingham-airport-net-zero-carbon-target/ 13
Why Gatwick’s Expansion Adds to the Aviation Carbon Headache: https://www.aef.org.uk/2019/08/15/why-gatwick-expansion-adds-to-the-aviation-carbon-headache/
14
Gatwick 2019 Masterplan: https://www.gatwickairport.com/globalassets/business--community/growing-gatwick/master-plan-2019/gatwick-master-plan-2019.pdf
15
2017 Aviation Forecasts: https://assets.publishing.service.gov.uk/government/uploads/system/uploads/attachment_data/file/878705/uk-aviation-forecasts-2017.pdf
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KEY ISSUES TO CONSIDER WHEN CHOOSING MOBILE CONCRETE PRODUCTION PLANTS FOR AIRPORT RUNWAY AND MAINTENANCE
Notes:
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