Summary

• The size of the runway and the volume of traffic have a significant impact on the cost of resurfacing.
• Materials and innovative techniques drive up the overall project costs.
• Strategic planning and preventive maintenance help reduce the cost of runway resurfacing.

Runway resurfacing is an important maintenance activity for airports to ensure the safety and efficiency of flight operations. However, it is also a complex and expensive undertaking. The cost of runway resurfacing can vary considerably depending on a number of factors, including the size of the runway, the materials used, the extent of the work required and the location of the airport.

Factors affecting runway resurfacing costs

Runway size and traffic volume

The size of the runway and the volume of traffic it handles are the main factors that affect the cost of resurfacing. Larger runways, such as those found at major international airports, require more materials and labor, which increases the price.

For example, according to NJ.com, Newark Liberty International Airport recently underwent a rehabilitation project on its busiest 10,000-foot runway. The size and high volume of traffic on that runway contributed to the complexity and cost of the project. According to a report by NJ.com, the rehabilitation project at Newark aimed to accommodate the runway’s heavy use while minimizing operational disruption.

Materials and techniques used

The choice of materials and resurfacing techniques also have a significant impact on costs. Traditional resurfacing involves laying a new layer of asphalt or concrete over the existing surface, which can be costly depending on the price of the materials and the thickness required. New technologies, such as asphalt mixes designed to withstand heavy aircraft loads or environmentally friendly materials, can drive costs up further.

According to Airport Improvement, San Francisco International Airport (SFO) opted for an expedited rehabilitation project that included repavement of the runway and replacement of lighting systems. The material selection and integration of the lighting replacement contributed to the overall project cost, according to Airport Improvement.

Project scope and additional work

Runway resurfacing projects often include additional work beyond simply laying new asphalt or concrete. For example, replacing runway lighting, upgrading drainage systems, and repairing taxiways are often required to ensure the long-term durability and safety of the runway.

At SFO, the renovation project also included upgrading the lighting systems, which increased the scope and cost of the project. Integrating these tasks is critical to ensure safety compliance and maintain optimal operational efficiency.

Time constraints and project schedule

The timeline for completion of a runway resurfacing project can greatly affect costs. Airports typically try to minimize disruption to operations, so projects are often scheduled during low-traffic periods or executed in phases to ensure some degree of continuous operations.

For example, Gatwick Airport was able to halve the cost and time of its runway renewal through optimised planning and the use of innovative construction techniques. According to TTG Media, Gatwick’s approach included shorter shifts during night closures, reducing the overall project duration and associated costs.

Geographical location and environmental factors

An airport’s geographic location and local environmental conditions can also impact the cost of resurfacing. Airports in regions with harsh weather conditions, such as extreme heat or cold, may require more durable materials and more labor to ensure the runway can withstand the local climate. In addition, airports in densely populated or environmentally sensitive areas may face higher costs due to stricter regulatory requirements and limited access to construction sites.

Current examples of runway resurfacing costs

Current renovation projects provide concrete examples of the costs associated with such projects:

• San Francisco International Airport: At SFO, the runway resurfacing project was completed on an accelerated timeline to avoid disruption to the flight schedule. While necessary, this approach will likely increase labor costs by requiring longer hours and additional personnel. In addition, replacing the lighting systems has increased the overall cost of the project. The exact cost will need to be detailed in the Airport Improvement Report, but the scope and speed of the project suggest a significant investment.

• Gatwick Airport: Gatwick’s innovative approach to runway renewal has halved the cost and time required for such projects. By reducing shifts and concentrating on night-time closures, Gatwick has significantly reduced labour and operating costs. A similar technique has been used at London Stansted, where daytime traffic is higher than at night. TTG Media reports that this strategy saved money and minimised the impact on airport operations, providing a valuable case study in cost-effective runway maintenance.

Cost-saving strategies for the renewal of runway surfaces

Airports can use several strategies to control and potentially reduce runway asphalt resurfacing costs:

• Innovative materials and techniques: The use of modern materials that offer greater durability can extend the life of the runway surface, reducing the frequency of resurfacing projects and associated costs over time. In addition, new resurfacing techniques, such as the use of fast-setting asphalt, can shorten project timelines and reduce labor costs.

• Delay strategies and preventive maintenance: Airports can also consider delaying remediation projects through preventive maintenance and minor repairs. As ASI Solutions points out, this approach can delay the need for full remediation by addressing minor issues before they escalate. However, this strategy requires careful consideration, as delaying for too long can result in greater damage and higher costs in the long run.

Renewing a runway is not an easy task

Runway asphalt resurfacing projects are critical to maintaining airport safety and efficiency, but they involve significant costs that depend on a variety of factors, including runway size, materials, project scope and location.

Recent projects at Newark Liberty International Airport, San Francisco International Airport and Gatwick Airport illustrate the range of costs and strategies involved in such projects. By using innovative materials, strategic planning and preventative maintenance, airports can keep costs under control while ensuring their runways remain in top condition for all passengers and aircraft safety.