Grace Industries LLC and joint venture (JV) partner Walsh Construction performed the rehabilitation of Runway 13L-31R and associated taxiways at John F. Kennedy Airport (JFK). The project began in April 2019, and was reopened for use on November 16, 2019. The existing 10,000 linear-foot-long deteriorating asphalt runway was milled and widened from 150 to 200 feet to make way for the new 18 inch thick Portland cement concrete runway, set atop a 2-inch asphalt leveling course. The concrete surface has been grooved as a safety enhancement. The associated taxiways, shoulder and erosion pavement were widened and improved to meet the FAA’s Airplane Design Group VI (ADG VI) standards.

The project scope included milling, paving, drainage improvements, pavement markings, upgraded lighting (electrical work provided by Grace affiliate Haugland Energy Group LLC), new guidance signs and sign foundations, realignment of taxiways and taxiways’ intersection, and replacement of the FAA’s navigational aid systems. Eastern Utilities Services provided directional drilling under the runway to save time and cost, compared to traditional open cut excavation methods. The extremely aggressive schedule called for work to be performed six days each week, over 10-12 hours shifts, both day and night; a challenge heightened when combined with the coordination of all work activities between the JV entities, subcontractors and specialized equipment, all within heightened security measures that come working on an active airfield at JFK.

Innovations and value engineering implemented on this runway rehabilitation by Haugland Group’s divisions changed the construction process from previous PANYNJ projects. More than 300,000 tons of material, including millings, soil and other debris were removed from JFK, and construction aggregate was brought back to the site. To increase efficiencies and reduce trucking costs, emissions and traffic congestion, construction materials were barged and back hauled through Inwood Material Terminal (IMT) with services provided by Midnight Trucking both to and from the IMT facility, and onsite at JFK. Further reducing the carbon footprint of this project, two temporary concrete plants were installed near the jobsite to minimize trucking needs.

This project not only improved the resiliency and safety of this key infrastructure asset while improving operational efficiency at one of the world’s busiest international airports, it also expanded and fortified the synergies between Haugland Group’s divisions. Haugland Group prides itself on progressively enhancing its operational practices as we work to build the most efficient construction processes possible.