The Hawaii Department of Transportation (HDOT) initiated a construction project to address a problem area on the Kahului Airport airfield located at the Taxiway A-C intersection. The area was prone to severe rutting, resulting in deflections and indentation of the asphalt pavement surface causing aircraft to get stuck. It required a mill and overlay repair every couple of months and was in urgent need of permanent repair.
GBI constructed three independent phases to fulfill the contract. Phase one consisted of construction of a temporary bypass taxiway to facilitate aircraft traffic during phase two construction. A strict timeline of 48 calendar days was scheduled to complete phase one scope, which included demolition of existing structures, relocation of airfield lighting and signs, excavation and fine-grade of infield work zone, and forming and placing more than 1,000 CY of P-501 concrete pavement. Runway closures were required to complete the work during weekends for a seven-hour window. To alleviate the loss of liquidated damages of up to $30,000 per hour due to runway closures, GBI scheduled crews’ activities at 15-minute increments over these seven-hour windows.
Phase two consisted of full-depth reconstruction with new rigid portland cement concrete (PCC) pavement. With 53 calendar days scheduled to complete phase two, GBI demoed and excavated 4,000 CY of existing asphalt concrete (AC) and subgrade to prepare the site for 1,100 tons of cement treated base (CTB), 1600 CY of P-501 concrete pavement and 1,300 ton of AC.
Phase three involved the demolition of the temporary bypass taxiway that was constructed in phase one. The area was restored to its original condition.
GBI was required to obtain security clearance and follow regulations regarding entering and exiting the area, operation of vehicles, and escort procedures, while maintaining strict visibility requirements. All personnel completed airport operation area training prior to working on site. GBI also received special training for air traffic control tower and aircraft pilot radio communication for this project.