McM Airport Design Report

198 Pages·2016·10.01 MB·English

by  Tom Headley

MCMINNVILLE MUNICIPAL AIRPORT
RUNWAY 4-22 REHABILITATION

AIP # 3-41-0036-016

ENGINEER’S
DESIGN REPORT

Prepared for:

City of McMinnville
230 NE Second St
McMinnville, Oregon 97128

Prepared by:

5331 SW Macadam Ave, #207
Portland, OR 97239
Phone: [phone]

April 2016
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McMinnville Municipal Airport 2016 Runway 4-22 Rehabilitation – Engineer’s Design Report

Table of Contents
1. SCOPE OF WORK .......................................................................................................................................... 1
2. PHOTOGRAPHS ............................................................................................................................................. 2
3. DESIGN STANDARDS .................................................................................................................................. 2
4. ENVIRONMENTAL PROTECTION........................................................................................................... 2
5. SOILS AND GRADING .................................................................................................................................. 3
6. DRAINAGE ....................................................................................................................................................... 4
7. PAVEMENT DESIGN .................................................................................................................................... 5
8. RECYCLING ..................................................................................................................................................... 5
9. MATERIAL AVAILABILITY ................................................................................................................... 6
10. PAVEMENT MARKING ........................................................................................................................... 7
11. SIGNAGE ...................................................................................................................................................... 7
12. LIGHTING .................................................................................................................................................... 7
13. FAA OWNED FACILITIES ...................................................................................................................... 7
14. NON-AIP WORK ........................................................................................................................................ 7
15. ENGINEER’S ESTIMATE ........................................................................................................................ 8
16. PRECISION APPROACH PATH INDICATORS ................................................................................. 8
17. MODIFICATIONS TO STANDARDS .................................................................................................... 8
18. DBE PARTICIPATION ............................................................................................................................. 9
19. BUILDINGS .................................................................................................................................................. 9
20. EQUIPMENT ............................................................................................................................................... 9
21. AIRPORT OPERATIONAL SAFETY .................................................................................................. 10
22. MISCELLANEOUS WORK ITEMS ..................................................................................................... 10
23. PREDESIGN MEETING NOTES ......................................................................................................... 10
24. MODIFICATIONS TO FAA SPECIFICATIONS………………..………………………………………….9
McMinnville Municipal Airport 2016 Runway 4-22 Rehabilitation – Engineer’s Design Report

Appendices
Appendix A Photographs
Appendix B Table of Design Standards
Appendix C Geotechnical Report
Appendix D Pavement Design
Appendix E Engineer’s Construction Cost Estimate
Appendix F PAPI Calculations
Appendix G Construction Safety and Phasing Plan
Appendix H Predesign Meeting Checklist and Notes
Appendix I Modifications to FAA Specifications
McMinnville Municipal Airport 2016 Runway 4-22 Rehabilitation– Engineer’s Design Report
1. SCOPE OF WORK
a. Narrative
Contractor bids, for the 2016 Runway 4-22 Rehabilitation Construction Project at the
McMinnville Municipal Airport, are expected to take place in the Spring of 2016 and
construction will commence the Spring of 2017. The project consists of the following major
work items:

1. Reconstruction of Runway 4-22 (narrowing from 5,420’x150’ to 5,420’x100’);
2. Reconstruction of five (5) taxiway connections to Runway 4-22 (within RSA limits);
3. Installation of pavement underdrains for new pavements;
4. Installation of drainage improvements in infield areas;
5. Removal of existing electrical system impacted by construction;
6. Installation of lighted guidance signs;
7. Installation of runway (HIRL) & taxiway edge lights;
8. Replacement of PAPI units (RW 4 and RW 22);
9. Crack repair and slurry seal of Runway 4 overrun area pavement (1000’x150’);
10. Construction of pavement markings; and
11. Runway 22 Threshold bar adjustment (by FAA).

Due to the poor pavement conditions of Runway 4-22, the proposed project involves full depth
reconstruction of the runway and the five connected taxiways within the runway safety area
(RSA) limits. The proposed improvements are in conformance with the current airport layout
plan.
b. Unique or Unusual Site Conditions
No unique or unusual site conditions exist that would impact the proposed improvements.
c. Age of Existing Pavement
Runway 4-22 was last reconstructed in 1992. The taxiways have not been reconstructed
since their original construction. The taxiways were originally constructed as follows; A1 in
2001, A2 in 1950, A3 in 1943, A4 in 1992, and D in 2009.
d. Current PCI Values
A Pavement Condition Index (PCI) study conducted in 2012 determined a PCI rating that
ranged from 61 to 58 (fair) for RW 4-22. That same study predicts the surface will
deteriorate to a PCI range of 50-46 (poor) by 2017.
e. History of Work Performed
Below is a historical summary of work performed on the McMinnville Municipal Airport.

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1992 Runway 4-22 Rehabilitation/Reconstruction
2001 Taxiway A Construction and Safety Area Modifications
2003 Tree/Obstruction Removal
2004 PCC Apron Reconstruction
2008 Runway 17-35 Reconstruction and Hangar Taxiway Construction
2009 Parallel and Infield Taxiway Construction
2. PHOTOGRAPHS
Photographs of the existing conditions of the project site are included in Appendix A.
3. DESIGN CRITERIA
A table of applicable FAA design standards for the Runway 4-22 Rehabilitation is included
in Appendix B. The current Airport Master Plan (2004) classifies Runway 4-22 as Airport
Reference Code (ARC) D-II. Based upon a pre-design study conducted under a prior grant
(AIP #3-41-0036-015), the decision was made and justified, to construct the runway at
100’ width and maintain an ARC D-II designation for the upcoming project. The design
criteria listed in Appendix B are in accordance with current FAA Advisory Circulars (AC).
4. ENVIRONMENTAL PROTECTION & PROJECT PERMITTING
Project permitting associated with the Runway 4-22 Rehabilitation project is expected to
be limited to the 1200-CA NPDES from the Oregon Department of Environmental Quality
(DEQ). The City currently maintains a 1200-CA permit from DEQ. The project will conform
to the permit requirements. It is possible that local building and/or electrical permits will
be required during construction. The contractor will be responsible for obtaining any
additional permits.
The upcoming project is not expected to impact wetlands. There are, however, anticipated
temporary impacts to the Streaked Horned Lark (SHL), which is federally listed as a
threatened species. FAA requires that all projects that receive agency funds comply with
the National Environmental Protection Act (NEPA). Based on the anticipated level of
environmental impacts associated with the upcoming project, FAA has decided that a
Documented Categorical Exclusion (Cat Ex) with a Biological Assessment (BA), to address
the impact to SHL, would be the appropriate level of documentation to show compliance
with NEPA. Century West has prepared the Documented Cat Ex and BA for FAA acceptance.
The BA has been distributed to the US Department of Fish & Wildlife (USFW) for agency
review. It is expected that USFW will issue a biological opinion and Incidental Take Permit

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in response to the BA. The environmental process is ongoing at the time of this report, and
is expected to be approved in February 2016.
5. SOILS AND GRADING
A geotechnical investigation was conducted at the airport on October 23 and 24, 2014. A
copy of the report is included in Appendix C.
Six exploratory test pits were excavated along the area of the proposed work on Runway 4-
22 and Taxiways A1-A4. Test pits were excavated to depths up to 7 feet below ground
surface. Soil profiles were logged and samples were taken from each test pit.
The Runway 4-22 pavement was cored at twenty-four locations. This work was done to
determine the composition of the existing pavement section. Soil profiles were logged and
samples were taken from each core location.
Copy of the reports summarizing the findings and recommendations from the geotechnical
investigation are included in Appendix C. The following is a brief summary of key
geotechnical considerations:
Ground Water: Slow seepage was observed at ±6 feet in TP-6. The geotechnical report
stated that this was most likely due to static groundwater fluctuations that seasonally occur
during the wet winter months. No other groundwater was found.
Frost Consideration: According to the soils investigation and report, the subgrade soils are
highly frost susceptible. The local building code recommends a frost penetration depth of
12”. Therefore, for new pavement sections a frost penetration depth of 12” was used in the
design.
CBR values
Two CBR tests were conducted as part of the soils investigation. Laboratory results for the
CBR were 1.7 and 1.8 when compacted to 95% of ASTM D-698. Since these values are
below the FAA minimum of 3 for pavement design, stabilization of the subgrade will be
required. In a memo dated December 2, 2015, methods for subgrade stabilization were
analyzed. A copy of the memo is contained in Appendix D. Stabilization methods included:
• Increased compaction (e.g. 100% of ASTM D-698, rather than 95%)
• Mechanical Stabilization (e.g. over excavation and placement of stabilization
material)
• Use of geotextile fabric and geogrid
• Chemical Stabilization (e.g. cement treatment, P-301)
• Compaction based on ASTM D-1557 (e.g. 92% to 95% of ASTM D-1557)

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McMinnville Municipal Airport 2016 Runway 4-22 Rehabilitation– Engineer’s Design Report
Based on the analysis conducted and described in the December 2, 2015 memo, the use of
soil cement treatment, using FAA Specification P-301, was selected as the most cost
effective approach to subgrade stabilization.
Using this approach, a CBR of 1.7 and subgrade stabilization using P-301 were used in the
design of the pavement section for the project.
Summary of Subsurface Materials
Runway 4-22 (C1-C13):
From surface to a depth of ±3.75” to ±5”: Asphalt Concrete (AC)
Below, ranging in thickness from ±17” to ±25”: Silty Gravel (GM)
Below, ranging in thickness: Clayey Silt
Runway 4-22 (C14-C18):
From surface to a depth of ±4” to ±7”: Asphalt Concrete (AC)
Below, ranging in thickness from ±2” to 3.27”: Base, crushed rock (GW)
Below, ranging in thickness from ±15” to ±26”: Silty Gravel (GM)
Below, ranging in depth: Clayey Silt
Connecting Taxiways (C22-C24):
From surface to a depth of ±4.5” to ±5”: Asphalt Concrete (AC)
Below, ranging in thickness from ±14” to ±20”: Sandy Gravel (GP)
Below, ranging in depth: Clayey Silt
6. DRAINAGE
Pavement underdrains will be constructed as part of this project. Current FAA guidelines
stress the use of underdrains to prevent saturated soil conditions beneath pavement
sections. Underdrains will be installed along the edges of all new pavement, along the
length of the Runway 4-22 and connector Taxiway rehabilitation.
Underdrains were designed according to the guidelines and procedures outlined in the
Drainage Manual published by the US Bureau of Reclamation. Underdrains will consist of 6-
inch diameter perforated corrugated polyethylene pipe. The underdrains will connect into
existing storm drains. Overall drainage patterns across the airfield will be maintained by
the current proposed improvements.
The project involves no ponds, or special features of any kind, that would attract water fowl
or create wildlife hazards.
The proposed project will not occur within a floodplain.

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7. PAVEMENT DESIGN
The pavement design for the project was initiated as part of a pre-design analysis, under
AIP #3-41-0036-015, and was summarized in a Technical Memorandum dated June 29,
2015. This memorandum established the fleet mix and preliminary soil parameters to be
used for design. A copy of this memorandum is included in Appendix D. A key assumption
in the memorandum was that a minimum subgrade CBR or 3 could be achieved, despite
soils testing that indicated CBR values of 1.7 to 2.3. The memorandum recommended
further analysis of subgrade stabilization to achieve a minimum CBR of 3 for pavement
design.
Subsequently, an analysis was performed and summarized in a memo dated December 2,
2015. A copy of the memo is included in Appendix D. This memo explored various forms of
subgrade stabilization in order to achieve a CBR of 3 for the pavement subgrade.
Stabilization methods included:
• Increased compaction (e.g. 100% of ASTM D-698, rather than 95%)
• Mechanical Stabilization (e.g. over excavation and placement of stabilization
material)
• Use of geotextile fabric and geogrid
• Chemical Stabilization (e.g. cement treatment, P-301)
• Compaction based on ASTM D-1557 (e.g. 92% to 95% of ASTM D-1557)
Based on the analysis conducted and described in the December 2, 2015 memo, the used of
soil cement treatment using FAA Specification P-310 was selected as the most cost effective
approach to subgrade stabilization.
Using this approach, a CBR of 1.7 and subgrade stabilization using P-301 were used in the
design of the pavement section for the project.
Copies of FAA form 5100-1, and the FAARFIRLD pavement design output are included in
Appendix D.
Runway 4-22 and Taxiways A1-A4
The existing pavement of Runway 4-22 and Taxiways A1-A4 is exhibiting distress related
to age and is due for reconstruction.

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An overlay is not recommended for the following reason:
• Existing cracks will reflect through to the new surface within a relatively
short timeframe, even with the use of modern crack sealing materials and
paving fabrics.
It is recommended that Runway 4-22 and Taxiways A1-A4 be reconstructed with new
pavement sections.
Design Criteria Runway 4-22 and Taxiways A1-A4
The new pavement section for Runway 4-22 and Taxiways A1-A4 are designed based on
the following criteria:
Design Aircraft Gulfstream G500
Gross Aircraft Weight 85,100 lb. gross weight
Aircraft Wheel Configuration Dual-wheel Gear
Utilizing FAA AC 150/5320-6 (Latest Version with NW Mountain Regional Modifications),
the new pavement section required for Runway 4-22 is:
Bituminous Surface Course 4” (P-401)
Aggregate Base Course 6” (P-209)
Soil Cement Base Course 6” (P-301)
Undisturbed Subgrade Undisturbed Soil (P-152)
Pavement Section Evaluation
It is recommended that plant mix bituminous pavement be used for the McMinnville
Municipal Airport. This type of mix will provide the strength and durability required by
FAA standards.
8. RECYCLING
Excavated material from runway and taxiway aprons are suitable for use in construction of
fills and subgrade formation.
9. MATERIAL AVAILABILITY
Materials for construction of the proposed project are expected to be readily available for
use.

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