08.03.2014 START OF WORKS • 02.06.2014 - 6.10 am FIRST TAKE OFF AT THE END OF WORK
International Orio al Serio airport. A ONE-OF-A-KIND operation.
2
The Orio al Serio airport
4
The challenge demand and figures
6
Meeting the strict schedule in 3 phases
8
Phase 1: runway end safety area 10
12
Phase 2: runway end safety area 28
16
Phase 3: runway
22
Planning and organisation Men and machines
24
Special custom asphalt
26
New LED lighting on the entire runway
28
400 km wiring
30
Vitali
The Orio al Serio airport
First in Europe for cargo
Fourth in Italy for passenger transit The Orio al Serio airport, near Bergamo, is the fourth largest Italian airport in terms of passenger transit and the leading cargo airport. Strategically located in the heart of Lombardy, less than 40 kilometres from the city of Milan, in just a few years it has reached peerless operating levels for this type of location. The impressive business growth naturally strained all the infrastructures, starting with the “wear� and maintenance conditions of the single take-off and landing runway. Logistic airport growth, still in progress and that will require Orio al Serio to adjust to even more demanding challenges, focused its growth strategies on runway adjustment to improve user services in terms of efficiency and safety.
2
3
The challenge demand and figures
Sacbo invested a total of 50 million Euro for this work which, in addition to flight infrastructure work, included runway light
2,000 LED AVL lights
500,000 square metre pavement area
control systems as well as plumbing and IT updates. The key “figures” that characterised Orio al Serio airport “A one-of-a-kind operation. Demanding from every
infrastructure renovations clearly express the extent and
standpoint: never before, indeed, had such radical
complexity of the job:
runway and taxiway work been successful on such
•
metres (corresponding to 80 football fields)
a significant airport, reducing downtime to less than three weeks”. The purchaser’s words, expressed by
•
Andrea Mentasti, Sacbo general manager, revealed the complexity of the work commissioned to the
Total new asphalt to be poured: 220,000 tonnes
•
Required horizontal markings: over 70,000 square metres (corresponding to 10 football fields).
impossible was not only reached, but work was
•
About 400 km of electric wires laid.
completed a day earlier than originally scheduled,
•
Installation of over 2,000 new flight navigation
avoiding every and all “non-conformities”.
200,000 t new asphalt
(corresponding to about 6,500 35.5 t lorries).
Vitali team. Yet the goal that seemed practically
4
Overall paved area subject to work: 550,000 square
assistance lights with LED technology.
400 km wiring 5
Meeting the strict schedule in 3 phases
fully met the strict schedule set by the purchaser. The first two phases were scheduled from March
08.03.2014 - 25.04.2014
RUNWAY END SAFETY AREA 10
PHASETWO
Work on flight infrastructures and other intervention elements at the Orio al Serio airport
Airport open
PHASEONE
Before schedule
Airport open
26.04.2014 - 12.05.2014 RUNWAY END SAFETY AREA 28
8th to May 12th, first on runway end safety area 10 (West) and then on runway end safety area 28 (East) with any interruption or limitation to fight activities. The purpose of the third and last phase, from May 13th to June 1st, was to complete renovations and repave the entire runway, links and taxiways. Monday, June 2, 2014, at 6 AM, the International
PHASETHREE
Orio al Serio airport runway was reopened for work, fully meeting the set schedule. The infrastructure was practically completed one day early.
6
Airport closed
13.05.2014 - 01.06.2014 THE RUNWAY 7
80
Pavement renovation and asphalt poured on a 90,000 square metre area
Creation of new
5,000 square metre concrete aircraft hangar lot
Levelling and load capacity increase of a 13,500
square metre
safety grass area located at the end of the runway
Installation of 410
LED lights on the runway 8
new
RUNWAY END SAFETY AREA 10
82
08.03.2014 - 25.04.2014
DEPARTURE / ARRIVALS
PHASEONE
RUNWAY END SAFETY AREA 10
RUNWAY END SAFETY AREA 10
4
10
11
DEPARTURE / ARRIVALS
75
80
Pavement renovation and asphalt poured on a
RUNWAY END SAFETY AREA 28
RUNWAY END SAFETY AREA 28
area
Creation of new
5,000 square metre
concrete aircraft hangar lot
Levelling and load capacity increase of
8,000 square metres
26.04.2014 - 12.05.2014
50,000 square metre
Installation of
280 new LED lights on the runway 12
PHASETWO
safety grass area at the end of the runway
RUNWAY END SAFETY AREA 28
14
15
800
THE RUNWAY
THE RUNWAY
of asphalt per minute
6 construction sites simultaneously running, each per shift with dedicated foreman, team and equipment Pavement renovation and asphalt poured on a
295,000 square metre area Demolition of the C link Installation of 1,800
new LED lights on the runway
16
PHASETHREE
4m
13.05.2014 - 01.06.2014
lorries per day
24 hours a day
7 days a week 1
2
5
3
h12.00
h13.00
h14.00
h15.00
h16.00
h17.00
h18.00
h19.00
h20.00
h21.00
h22.00
3
h23.00
h00.00
02.06.2014 - 6.10 am FIRST TAKE OFF AT THE END OF WORK
08.03.2014 START OF WORKS
h01.00
h02.00
h03.00
h04.00
h05.00
h06.00
h07.00
h08.00
h09.00
h10.00
h11.00
Challenges are met with numbers
To meet job expectations and the strict schedule, Vitali and its partners put an
Technologies were adequately coordinated in use to
A carousel of vehicles of every shape and kind, continuously moving 24/7. The work plan
The milling and laying phase that concerned an overall surface of over 300,000 square
exceptional work team into place, both on the human resource level and concerning
optimise work time, results and costs.
included 300 workers per shift, 600 latest generation vehicles equipped with GPS systems
metres included some of the most innovative machines on the world market with
to maintain project benchmarks.
exceptional performance.
the vehicle fleet and machinery.
WORK SITE 3
WORK SITE 2
RUNWAY END SAFETY AREA 10
WORK SITE 1
WORK SITE 6
900 workers
600 latest generation vehicles
WORK SITE 4
800 lorries per day
RUNWAY END SAFETY AREA 28
WORK SITE 5
4 mt asphalt per minute
In the third phase 6 worksites open simultaneously and perfectly coordinated
One foreman One team Dedicated vehicles for each site, on 3 shifts
THE RUNWAY
18
19
20
21
Planning and organisation Men and machines 900 workers were involved divided into 3 shifts.
600 latest generation vehicles
7 days a week, 24 hours a day. Over 600 latest generation vehicles with GPS systems to maintain project benchmarks. Regarding the sub-foundation phase, GRADERS and DOZERS also equipped with GPS were used. The milling and laying phase concerned a total surface over 550,000 square metres using some of the
GPS technology on all vehicles
most innovative machines on the world market such as the BOMAG BF800 finishing machines, WIRTGEN W210 mills and WR 2000 stabilisers with exceptional performance in addition to rollers, mechanical shovels, excavators, telescopic lifters, etc. 2 cement mixers and sieves were placed on site
900 workers on 3 shifts
to crush excavation scrap material.
22
23
Special custom asphalt
To ensure the maximum reliability and durability of the new Orio al Serio runway asphalt strip, Vitali engineering designed and created a special bitumen composite using HARD bitumen and fibres with exceptional technicalfunctional properties meeting ENAC and ICAO technical-regulatory requirements. The strip is 30 centimetres thick.
200,000 tonnes of asphalt
The modified bitumen provides the asphalt with both higher elasticity and greater resistance. To ensure work accuracy, asphalt was laid with the hot joint method on the entire runway.
24
a custom recipe
25
New LED lighting on the entire runway
The new Orio al Serio airport lighting provides 70% energy savings over traditional lighting systems. In addition to the lights, all navigation assistance lighting systems were renovated.
2,000 new lights with LED technology
These are latest generation systems that allow all runway areas to be remote controlled and fault troubleshooting in real-time.
26
27
400 km wiring
One of the accessory works that should not be overlooked is the full replacement of cable ducts and wiring for a total of 400 km. This operation aimed to update the local network and runway system infrastructure. These updates allow for savings in terms of maintenance and improved overall efficiency.
28
29
Vitali real estate development
Work on the Orio al Serio airport runway is an extremely significant way to evaluate the Vitali and its partners’ potential and work methods. Proof of how an organisation able to combine tested methods
special demolitions environmental reclamation|decommissioning
and innovation can achieve extraordinary results, going against the trend of delays and problems that often characterise infrastructural works in Italy. A virtuous example that speaks more than words on Vitali’s identity: a group specialised in highly complex
infrastructures roads|highways|airports
work, that bases its competitive range on the professionalism of over 400 experts that make up the team and the availability of an advanced machinery
your construction partner
pool. Sure results in guaranteed time emerge from this synergy. production asphalt|concrete|inert material
engineering
30
31
Vitali S.p.A. via Alberto da Giussano, 15 - 20145 Milano (MI) email: info@vitalispa.it WWW.VITALISPA.IT