Airport runway rehabilitation is among the most demanding categories of infrastructure work. Unlike road paving, runway projects require exacting tolerances, specialized mix designs, and coordination with active airfield operations. The recent rehabilitation of Runway 5/23 at Morristown Municipal Airport in New Jersey demonstrates how proper planning, modern equipment, and experienced contractors come together to restore critical aviation infrastructure. Understanding the Key Facts About Construction Project Life Cycle Phases provides a useful framework for appreciating how each stage of a runway project unfolds from initial assessment through final acceptance.
1. Understanding Airport Runway Rehabilitation Projects
Morristown Municipal Airport sits three miles east of downtown Morristown in the Whippany section of Hanover Township, New Jersey. It is classified as a public reliever airport, designed to provide additional capacity when primary commercial airports reach their operational limits. With over 72,000 aircraft operations per year nearly 198 per day the airport serves as a vital piece of regional transportation infrastructure. The facility covers 625 acres and features two asphalt runways: Runway 5/23 measuring 6,000 feet by 150 feet, and Runway 13/31 at 4,000 feet by 150 feet.
Why Runway Rehabilitation Becomes Necessary
Over time, runway pavement deteriorates under repeated aircraft loading and environmental exposure. Runway 5/23 was carrying heavier loads than its original design anticipated, leading to severe cracking from both wear and age. The centerline crown had fractured and was settling excessively, creating an uneven surface that pilots found problematic.
As David Jones with Delta Airport Consultants explained, the goal was to rehabilitate the center 50-foot-wide keel of the pavement by removing and replacing the previous two overlay lifts. These lifts exhibited signs of excessive voids and aggregate cracking. The project also needed to restore the center 18-inch crown that had fractured and was settling.
Phased Approach to Match Available Funding
Airport rehabilitation projects often span multiple budget cycles. The Runway 5/23 project was structured in phases to align with available funding. Phase 2 covered 1,200 feet of the runway’s 6,000-foot length. This phased strategy allows airport authorities to maintain operational continuity while systematically upgrading infrastructure as budgets permit. Proper Construction Project Scheduling Methods Tools and Best Practices become especially important when a project is split across multiple years and must coordinate with ongoing airfield operations.
2. Project Planning and Material Specifications for Runway Pavement
Smith-Sondy Asphalt Construction Company of Wallington, New Jersey was selected to execute the runway rehabilitation in early August. Founded in 1946, Smith-Sondy is a high-volume paving contractor handling road reconstruction, bridge-deck repairs, and paving throughout northern New Jersey and sections of New York. The company holds memberships in the National Asphalt Paving Association, the National Utility and Transportation Contractors Association, and the New Jersey Asphalt Paving Association.
Milling and Pavement Removal Specifications
Riverview Milling served as the milling subcontractor under Smith-Sondy. The milling scope included:
- Milling to a 9-inch depth with 1-foot edge steps
- 5-foot to 15-foot steps at the end of every 3 inches of thickness for transitioning into existing pavement
- Crack repair as required throughout the work area
- Placement of an asphalt overlay fabric to prevent reflective cracking
FAA-Graded Mix Design Requirements
The project specified an FAA P-401 SP Superpave mix, supplied by Tilcon. This is the standard Federal Aviation Administration specification for asphalt pavement at airports. The mix was placed in three 3-inch lifts for a total thickness of 9 inches. A total of 3,500 tons of asphalt was laid during Phase 2.
Jack Meyer, project superintendent for Smith-Sondy, noted that the preexisting runway surface had become uneven over time. The fabric underlayment installed between lifts played a critical role in preventing reflective cracking from propagating upward through the new pavement layers.
Complete Work Scope Summary
The full scope of the runway rehabilitation project included the following activities:
- Mill existing pavement to 9-inch depth with stepped transitions
- Repair cracks in the remaining pavement structure
- Place asphalt overlay fabric over prepared surface
- Place three 3-inch lifts of FAA P-401 SP Superpave mix
- Provide temporary pavement markings for airfield operations
- Allow 30 days of cure time before grooving
- Groove the pavement surface for skid resistance
- Apply final markings with glass beads for reflectivity
3. Equipment Selection: The Role of Modern Asphalt Pavers in Runway Projects
Smith-Sondy had recently invested in a new Volvo P7110 tracked paver purchased from Penn Jersey Machinery, a Volvo dealer in Frenchtown, New Jersey. This machine was deployed directly on the Morristown Airport project. Equipment selection is one of the critical Factors Considered Before Undertaking a New Construction Project, particularly when working to FAA specifications on an active airfield.
Key Features of the Volvo P7110 Paver
| Feature | Specification | Benefit on Runway Project |
|---|---|---|
| Engine | 235-hp Volvo D8 Tier 4i | Sufficient power for 9-inch deep lifts at width |
| Emission Control | DPF with active regeneration | Non-interruptive operation during paving |
| Platform Design | Low profile, single level | Unobstructed view of material flow |
| Feed Sensors | 4 ultrasonic sensors (standard) | Automatic material flow regulation |
| Screed | Electric-heated Omni 318 with vibratory tampers | Good initial compaction in thick lifts |
| Grade Control | Topcon automated system | Precise joint matching for smoothness |
Why This Paver Was Chosen
Company president Joseph C. Smith emphasized that reliability is the most important quality in a paver, followed by serviceability and ease of operation. The company had been loyal to Blaw-Knox equipment since purchasing its first used paver in 1978, and Volvo had since acquired and upgraded the Blaw-Knox paver line. Smith noted that the company typically replaces pavers every five years but waited seven this cycle due to concerns about Tier 4 engine designs making machines taller and causing obstruction with trees during municipal paving work.
The P7110’s low-profile design proved advantageous on the runway project. The single-level platform gave operators an unobstructed view of material flow from the truck through the auger tunnel to the end gate. Four standard ultrasonic sensors automatically regulated hopper delivery and material flow to match the paver’s speed, ensuring smooth and consistent paving.
Meyer reported that the sonic feed sensors helped maintain a smooth, consistent feed of material from the hopper to the screed. The electric-heated Omni 318 screed with vibratory tampers delivered good initial compaction, which is essential for achieving density requirements in thick runway pavement lifts. Following the paver were a Caterpillar CB54 and Ingersoll Rand DD118 and DD110 rollers for final compaction.
Grade Control for Runway Smoothness
A Topcon automated grade system from Cleary Machinery was mounted to the paver for joint matching. Meyer stated that this system produced perfectly matched joints, contributing to consistent joint density and overall pavement smoothness. For a runway that had developed a reputation for being bumpy among pilots, achieving a smooth final surface was a primary quality objective.
4. Overcoming Construction Challenges on Active Airfield Pavements
Runway rehabilitation projects present unique logistical challenges that distinguish them from standard road paving work. These projects operate within strict scheduling windows, face substantial financial penalties for delays, and must coordinate multiple subcontractors and equipment spreads on an active airfield. The Construction Project Life Cycle Phases in Life Cycle framework helps explain how each phase from planning through closeout must account for airfield-specific constraints.
Scheduling and Weather Risk Management
The project had a 13-day window during which the crew could work at any time. Liquidated damages for exceeding this window were substantial, meaning no time could be wasted. Weather delays represented a significant risk, as rain or high winds could halt paving operations entirely.
The team managed to complete the work four days ahead of schedule by capitalizing on favorable weather and working longer days. Meyer credited the early finish to a well-coordinated team effort and well-running equipment that minimized downtime.
Coordination Across Multiple Workstreams
Successful runway rehabilitation demands tight coordination among several key participants:
- Prime contractor: Smith-Sondy managed overall project execution and asphalt paving
- Milling subcontractor: Riverview Milling handled precision pavement removal to specified depths and transitions
- Material supplier: Tilcon provided the FAA P-401 SP Superpave mix
- Equipment dealer: Penn Jersey Machinery supplied and supported the Volvo P7110 paver
- Grade control supplier: Cleary Machinery provided the Topcon automated system
- Survey crew: Constantly monitored grades throughout the paving process
Mel Oxenreider played an integral role in assisting with coordination efforts, ensuring that all components from material delivery to equipment logistics worked in harmony.
Lessons for Future Airport Rehabilitation Projects
The Morristown Municipal Airport project offers several takeaways for contractors and airport authorities planning similar work:
- Phased project delivery allows airports to match rehabilitation scope to available funding without shutting down critical infrastructure
- Modern pavers with ultrasonic feed sensors and automated grade control deliver the precision required for FAA-specified pavement smoothness
- Low-profile equipment designs can be advantageous in airfield environments where sight lines and clearance matter
- Fabric underlayments between lifts are effective at preventing reflective cracking in runway overlays
- Building buffer time into compressed schedules and maintaining reliable equipment are essential for completing work within liquidated-damage windows
- Vibratory screeds provide the initial compaction needed to meet density specifications in thick lift airport paving
Runway rehabilitation is a specialized discipline within asphalt paving that demands attention to material science, equipment capability, and construction management. The successful completion of Phase 2 of Runway 5/23 at Morristown Municipal Airport demonstrates how an experienced contractor with the right equipment and planning can restore aging airfield pavement to serviceable condition, improving safety and ride quality for the thousands of aircraft operations that depend on it each year.