Gary Chicago International Airport Runway Rehabilitation
The Client
The Gary / Chicago International Airport is known as Chicago’s “third airport,” after the larger and more well-known O’Hare and Midway Airports. Seeking to increase its operational ability in order to better serve bigger aircrafts and more flights, Chicago / Gary Regional Airport Authority partnered with the Superior Construction team and several other highly skilled crews to rebuild the Airport’s runways in this expedited, three-phase project.
Project Fast Facts
Client: Chicago / Gary Regional Airport Authority
Location: Lake County, IN
Work Performed: Phase 1-2: Demolition of the existing runway, placing 30,000 CY of concrete pavement via an on-site batch plant, state-of-the-art stringless paving system, milling | Phase 3: Runway repaving, raising the runway grade 13”, raising edge lighting, raising centerline lights
Project Schedule: Phase 1-2: 30 days (completed 2 days ahead of schedule) | Phase 3: 21 days (completed one day ahead of schedule)
Completion Date: Phase 1-2: May 19, 2018 | Phase 3: May 21, 2019
The Work
Phases 1-2: Superior worked closely with the Airport, FAA, the design engineer, and all subcontractors and vendors to eliminate disruptions to ongoing airport operations as we rebuilt the east side of the main runway in phases one and two.
Due to the extremely aggressive schedule, Superior partnered with concrete supplier Ozinga to utilize a portable batch plant. Leveraging this batch plant allowed for 30,000 CY of concrete placement in just 12 pouring days, decreasing the project schedule by two days and decreasing waste and overall project footprint.
Superior used stringless paving methods by leveraging Leica TS16 robotic total stations and a Leica Machine Control SP84 Paver. This made continuous paving and transmission of real-time information possible for both our team and our milling subcontractor. Utilizing this state-of-the-art technology ensured concrete thickness control and finish grades, while eliminating milling inconsistencies.
Phase 3: Again using a portable concrete batch through our partners at Ozinga, we completed the runway’s transition from asphalt to concrete through more than 100 million pounds of construction materials. Work included runway repaving, raising the runway grade 13 inches, raising edge lighting, and raising centerline lights — accomplished despite inclement weather 14 out of the 19 days allotted. These improvements reduced pooling water, ultimately increasing the lifespan and decreasing maintenance needs and downtimes for repairs. They also provide aviators with better access points to and from the runways.
The Result
Due to extensive pre-planning, close coordination among teams, and around-the-clock dedication, phases 1-2 were completed two days ahead of schedule, despite the extremely tight 30-day runway closure. Our work resulted in a more capable airport and overall economic development for both the Airport and the city of Gary.
Phase 3 required perfect execution to ensure the FAA-mandated, 19-day / 8-hour runway closure was achieved. The entire team used effective communication to change sequencing, working around the rain and adjusting work schedules and material delivery to ensure successful project completion one calendar day ahead of schedule. This allowed the Airport to resume operations sooner than anticipated, adding money to their bottom line and decreasing their operational deficit. The improved runway means the Airport is now able to accept international flights, further increasing its value.
Project Awards
Construction Risk Partners Build America Awards, 2020, Associated General Contractors of America (AGC)
Union Project of the Year, 2019, The Association of Union Constructors