Tag Archives: The Lane Construction Corporation

Commercial Service & Military Airports – Silver Award

Silver Award –Naval Air Station Oceania, Virginia Beach, VA

Contractor: The Lane Construction Corporation*

Owner: U.S. Navy, NAS Oceania

Engineer: Johnson, Mirmiran & Thompson, Inc.

From outward appearances, this runway reconstruction and lighting replacement project at Naval Air Station Oceana in Virginia Beach, Va., may have seemed like any ordinary project, but the issue of unsuitable soils meant the construction team had to take some extraordinary steps to keep the project on track.

Initial plans called for the removal of 25,000 CY of unsuitable soil, but the contractor removed and replaced that quantity of soil during only the first 10% of the runway grading. The Lane Construction Company worked closely with the Naval Facilities Engineering Command (NAVFAC) and used a combination of methods and materials, including undercutting, soil cement, cement treated aggregate, and even testing and receiving approval to place cement treated aggregate on top of the old runway, which was constructed with concrete pavement in 1942, was about 22 in. below finish grade. Making matters worse, the contractor had to remove several asphalt overlays and a section of 8 in. concrete from the 1980s.  

The contractor worked collaboratively with the Navy to minimize cost and scheduling impacts.  Although the Navy budgeted $4.5 million for the subgrade work, Lane’s costs were only $1.65 million. To reconstruct the main runway (14R/32L) and the adjacent areas, the contractor placed 6 in. of crushed concrete, followed by 6 in. cement-treated aggregate and 12 to 15 in. of concrete pavement to reconstruct the 1.5 mile runway, including 4 intersections.  In all, a total of 197,581 SY of concrete was placed at a total cost of under $16.5 million.

The overall project was broken into 100 separate phases to help maintain traffic and power and controls of the lighting system.  Night paving allowed the contractor to take advantage of cooler temperatures and reduced air traffic. A 1.2 mile haul road constructed around the runway helped the crews avoid crossing active runways. The project also included new lights on all taxiways and runways, as well as replacement of equipment in the control tower and in new electrical vaults.

Despite closing two of the four runways, aircraft operations did not decrease. As the construction moved forward, the Navy continued its operations with an average of 800 aircraft per day, and during the span of the project, the Air Station Oceana saw more than 1,000,000 flight operations, supported over 100,000 passenger operations, handled 8,000 transient aircraft, and processed more than 1,200 detachment requests. 

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* ACPA member.

Concrete Pavement Restoration (GOLD)

I-40 CPR Express Design-Build Project, Winston-Salem, NC
Contractor: The Lane Construction Corporation
Owner: North Carolina Department of Transportation
Engineer: Progressive Design Group, Inc.

The goal of this project was to improve the cloverleaf interchange of I-40 and US52 to handle expected traffic volume increases from a two-year shutdown of Business 40. The project involved removing and replacing existing damaged jointed concrete slabs and placing new, jointed concrete pavement.

Facing a requirement to remove and replace significant amount of concrete pavement a single construction season, would have been challenging enough, but The Lane Construction Company also faced many other factors, including:

  • Managing restrictions that limited lane narrowing or lane closures between 5 a.m. to 7 p.m. (Monday thru Friday).
  • Completing undercuts that were required ahead of placing new concrete pavement, all within the same shift during the week or within the same weekend closure.
  • Encountering continuously reinforced concrete or extra depth concrete that required modification of concrete removal methods.
  • Contending with reduced work areas and night work.
  • Managing high-volume, high-speed traffic on both I-40 and US52.
  • Managing the project around event-related restrictions, which included all holidays, Wake Forest football home games, the 10-day long Dixie Classic Fair restrictions (which extended from 6 a.m. to 9 p.m.), Bowman Gray Stadium Racing events, and Winston-Salem State football games.
  • Coordinating with surrounding projects and manage resources using a non-conventional work schedule.

Because of lane closure restrictions, the contractor used a very high early-strength concrete mixture to achieve the 400 psi flexural strength requirement prior to opening to traffic. Lane Construction used a combination of volumetric rapid set concrete during nightly closures and an accelerated, 12 hour/24 hour ready-mixed concrete when extended closures were permitted.

Equally important was a thorough work plan Lane Construction developed to meet the many challenges, while also maintaining productivity and quality. One factor that could have impacted quality was the risk of damage to recently placed concrete while removing concrete from adjacent areas. To protect the new concrete, expansion material was placed between the new and existing concrete pavement intended to be removed. Despite significant challenges, this exceptional project was delivered on time.

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