Brochure Orio al Serio Airport low_ENG

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.

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The Orio al Serio airport

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The challenge demand and figures

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Meeting the strict schedule in 3 phases

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Phase 1: runway end safety area 10

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Phase 2: runway end safety area 28

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Phase 3: runway

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Planning and organisation Men and machines

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Special custom asphalt

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New LED lighting on the entire runway

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400 km wiring

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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.

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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

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metres (corresponding to 80 football fields)

a significant airport, reducing downtime to less than three weeks”. The purchaser’s words, expressed by

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Andrea Mentasti, Sacbo general manager, revealed the complexity of the work commissioned to the

Total new asphalt to be poured: 220,000 tonnes

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Required horizontal markings: over 70,000 square metres (corresponding to 10 football fields).

impossible was not only reached, but work was

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About 400 km of electric wires laid.

completed a day earlier than originally scheduled,

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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

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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.

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Airport closed

13.05.2014 - 01.06.2014 THE RUNWAY 7

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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

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08.03.2014 - 25.04.2014

DEPARTURE / ARRIVALS

PHASEONE

RUNWAY END SAFETY AREA 10

RUNWAY END SAFETY AREA 10

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10

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DEPARTURE / ARRIVALS

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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

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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

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PHASETHREE

4m

13.05.2014 - 01.06.2014

lorries per day

24 hours a day

7 days a week 1

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5

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h12.00

h13.00

h14.00

h15.00

h16.00

h17.00

h18.00

h19.00

h20.00

h21.00

h22.00

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h23.00

h00.00

02.06.2014 - 6.10 am FIRST TAKE OFF AT THE END OF WORK

08.03.2014 START OF WORKS

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h02.00

h03.00

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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

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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.

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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.

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a custom recipe

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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.

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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.

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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

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Vitali S.p.A. via Alberto da Giussano, 15 - 20145 Milano (MI) email: info@vitalispa.it WWW.VITALISPA.IT