Sierra – Uniform Taxiway Intersection Slab Replacements
Melbourne Airport taxiway slab replacement – Sierra – Uniform Taxiway Intersection.
Melbourne Airport engaged Antoun to deliver one of the most significant Rapid Set Concrete projects in the aviation sector — the replacement of 24 deteriorated airport concrete pavement slabs at the Sierra–Uniform Taxiway intersection.
Due to decades of heavy aircraft traffic, the airport slabs had experienced significant wear and deterioration. This was one of the largest airport slab replacement using Rapid Set concrete technology. It also had to be completed at one of Australia’s busiest 24-hour airport’s without impacting operations or passenger experience.
Background – A Critical Airport Pavement Upgrade
The Sierra–Uniform Taxiway intersection is a vital part of Melbourne Airport’s airport infrastructure network, connecting multiple taxiways and aprons. Any downtime here can cause major disruption to flight schedules.
Given the operational importance of the intersection, traditional methods were not feasible due to long setting times. Instead, Antoun utilised its Rapid Set Concrete technology and systems to complete the slab replacements overnight, allowing aircraft movements to resume each morning without delay.
Scope of Works – Precision in Limited Time
The program involved high-intensity airport pavement repair activities, all within a six-hour nightly window:
- Demolition and removal of existing airport slabs.
- Installation of new Rapid Set Concrete slabs to achieve full strength within hours.
- Decommissioning, replacement, and re-energisation of impacted Airfield Ground Lighting (AGL) systems.
- A full-scale trial slab replacement before commencement to validate sequencing and methodology.
- Management of PFAS contaminated airport concrete in compliance with environmental regulations.
Managing Risk in a Live Airside Environment
Working airside at Melbourne Airport required strict safety, quality, and environmental management. The airport slab repairs were carried out with:
- Zero operational disruptions across the six-week program.
- No extended closures to taxiways or aprons.
- Continuous collaboration with Melbourne Airport’s infrastructure delivery and airfield operations teams.
The Results – A Repeatable Airport Slab Replacement Solution
Antoun delivered a repeatable methodology for airport slab replacements that can be applied to future programs without impacting flight operations. Over six weeks, the project achieved:
- No aircraft delays during works.
- Pavement upgraded with airport high early strength concrete for maximum durability.
- Enhanced performance and extended service life of the airport pavements.
From design through to final handover, Antoun worked closely with Melbourne Airport’s safety, operations, and environmental teams to deliver the works on time, on budget, and with zero disruption to passengers.
Contact Antoun to discuss how our expertise and bespoke equipment can help you on your next project.