Independence Excavating (IX) was awarded the final phase (Phase 4) of the North Airfield Improvements project in 2020, with construction slated to get underway in April of 2021. The $15-million-dollar contract with City of Cleveland Department of Port Control (DPC) consisted of multiple phases with a very aggressive schedule that had to be met in order to keep the Airport operational at all times. This project focused on the realignment of Taxiways Juliet and Sierra, as well as removal of the final piece of Taxiway Charlie at the north end of the airfield.

The project was performed in two main phases, each with several sub phases that had to be performed at night in order to maintain air traffic. Phase 1 focused on the realignment of Taxiway Juliet directly adjacent to the Terminal. Constant coordination with Airport Operations was critical to keep the impacts to arriving and departing flights to a minimum. In order to begin phase 2, which consisted of the bulk of the work, the 2nd of the Airports 3 runways had to be shutdown, leaving them with 1 runway for the bulk of the summer. Emergency and contingency plans had to be continually discussed in the event that the only remaining runway would have to be shut down for any reason. IX was able to propose a slightly altered phasing plan that enabled the 2 phases to overlap slightly, which created a more productive work schedule as well as a safer taxiway crossing to access our work area.

Major demolition scope items in this contract included removal of over 150,000 tons of existing concrete and asphalt taxiways, various storm sewer removal and grouting, electrical duct bank, lighting, and signage removal. All P-219 aggregate base for new concrete areas and 57’s needed for new drainage installation was crushed and screened on site. Included in the site work scope was over 3400 LF of various size RCP storm sewers ranging in size from 24” to 54”, approximately 7000 LF of 6” PVC underdrain, 47,000 SY of subgrade stabilization and grading of aggregate base for new pavement areas.

The new concrete pavement for this project consisted of a 8” thick layer of lean concrete base followed by a 16” thick layer of Portland cement concrete. IX was able to utilize our Rexcon batch plant setup on site to batch the 30,000 CY of concrete needed to complete this work. The concrete paving was achieved using a combination of machine placements and hand pours. Our machine placements utilized 2 stringless slip form pavers, a Gomaco 2800 and a G & Z S600. Having the flexibility to use 2 pavers was paramount in our efforts to complete this work due to the aggressive schedule and varying joint patterns. In addition, IX self-performed all of the sawcutting and joint sealing for the new concrete pavement. Additional items in the scope that had to be perfectly coordinated were all of the new electrical duct banks, edge lights, airfield signs, asphalt paving for shoulders, seeding and sod installation, and pavement markings.

Well above average rain fall combined with COVID related material and labor shortages also added to the many challenges faced while completing this project.