Building Airport Runways: Engineering Challenges And Solutions

Building an airport runway is no small feat, but it's not impossible either. In fact, of the more than 19,000 airports in the US, over 14,000 are privately owned. If you're thinking of building your own runway, there are a few things you should keep in mind. Firstly, you'll need to ensure you have enough space—at least an acre of land is recommended. You'll also need to consider the type of aircraft you'll be accommodating, as this will impact the length and width of your runway. Other factors to contemplate include prevailing winds, soil composition and stability, drainage, elevation grade, runway length and markings, lighting, approaches, obstacles, and building setbacks.

When it comes to construction, you'll need to grade the land, pack the dirt, and add a surface material such as grass, gravel, or asphalt. If you're building a grass runway, you'll need to choose the right type of grass and ensure proper drainage to avoid water buildup, which can be dangerous for landing planes. It's also important to familiarise yourself with any relevant rules and regulations, such as those set by the Federal Aviation Administration (FAA) in the US, and to obtain any necessary permits or approvals from local authorities. Building a runway can be a complex and time-consuming process, but with careful planning and perseverance, it is achievable.

Choose a location

Choosing a location for your runway is a critical step in the process of building an airport. Here are some key factors to consider when selecting the right site:

Accessibility and Proximity

The chosen location should be easily accessible to those who will be using the airport. Consider the surrounding infrastructure, such as roads, public transport, and proximity to population centres. Ensure that the site is not too remote, as this may cause inconvenience for travellers.

Environmental Impact

Conduct a thorough environmental impact assessment of the potential site. Consider factors such as habitat protection, noise reduction, and pollution control. Assess the surrounding terrain and ensure that the runway's orientation takes into account the prevailing winds to optimise aircraft performance. Also, be mindful of any nearby power lines and cellphone towers that could pose a risk to aircraft.

Land Availability

Ensure that there is sufficient land available to accommodate the runway and any associated infrastructure, such as taxiways, terminals, and parking facilities. As a rule of thumb, a 2,000-by-75-foot runway will require approximately 3.5 acres of land.

Regulatory Compliance

Research and adhere to any local, state, and federal regulations regarding airport construction. Consult with aviation authorities, such as the Federal Aviation Administration (FAA) in the United States, to obtain the necessary permits and approvals. In the US, for example, private airfield owners are required to submit a Landing Area Proposal (LAP) to the FAA at least 90 days before beginning construction.

Future Development

When choosing a location, consider the potential for future expansion. Master planning should include forecasting future airport needs, such as the possibility of adding more runways or extending existing ones to accommodate larger aircraft. Ensure that the chosen location can support such developments in the future.

Plan the design

Planning the design of your runway is a complex process that requires careful consideration of various factors. Here are some key steps to help you plan the design of your airport runway:

Step 1: Understand the Regulations

Before you begin designing your runway, familiarize yourself with the relevant regulations and guidelines. In the United States, the Federal Aviation Administration (FAA) has specific rules and standards that must be followed for runway construction. These standards are outlined in Advisory Circulars (AC) such as AC 150/5300-13, Airport Design, and AC 150/5390-2, Heliport Design. Make sure to review these documents to ensure your runway design complies with the necessary regulations.

Step 2: Choose the Location

The location of your runway is crucial. Consider factors such as the availability of land, proximity to existing airports or airspace restrictions, and any environmental impacts. Select a site that offers ample space for the runway and any necessary infrastructure, taking into account the length and width requirements for the type of aircraft you plan to accommodate. Ensure that the location does not have any obstacles or restrictions that may interfere with takeoff and landing paths.

Step 3: Determine the Runway Specifications

Decide on the length, width, and surface material of your runway. The specifications will depend on the type of aircraft you intend to use, the local weather conditions, and the frequency of use. For example, larger aircraft or frequent flights may require a longer and wider runway, while certain aircraft may need a paved surface instead of grass. Consider the soil composition and stability, drainage, elevation grade, and lighting requirements when designing the runway.

Step 4: Consider Additional Infrastructure

In addition to the runway itself, you will need to plan for other infrastructure, such as taxiways, aprons, and buildings. Determine the number and layout of taxiways and aprons, ensuring they provide safe and efficient movement for aircraft. Decide on the number and placement of terminal buildings, hangars, and any other necessary structures. Consider the placement of fuel farms, navigation aids, and lighting systems to support aircraft operations.

Step 5: Consult with Experts

Engage the services of qualified professionals, such as aviation attorneys, engineers, and consultants, to ensure your runway design complies with legal, safety, and operational requirements. Their expertise will help you navigate complex issues, such as establishing clearance and avigation easements, ensuring your runway meets insurance requirements, and optimizing the runway design for efficient aircraft operations.

By following these steps and carefully planning each aspect of your runway design, you will be well on your way to creating a safe and functional airport runway.

Budget for construction and maintenance

The cost of building an airport runway varies depending on the desired length, width, and surface material. For example, a 2,500-foot (ft) by 75-foot concrete runway is estimated to cost $1 million, while a grass runway can be constructed for as little as $100 per 0.3 hectares (or roughly $400 per acre).

When constructing a concrete runway, several factors contribute to the overall cost:

• Dirt work, including site treatment, drainage, culverts, slope, and compaction, can cost around $250,000.
• Materials such as concrete, stone, rebar, and sand for a 7-inch thickness can amount to $500,000.
• Labor for pouring concrete can reach $100,000.
• Auxiliary features like lights, painting, a windsock, a hangar, and electrical work may add another $100,000.

On the other hand, a grass runway is a more affordable option. The real cost lies in the preparation, including soil testing, fertilisation, aeration, and grading. Grading typically costs around $1 per square foot, and you may need to install drains to manage water runoff. Finally, grass seed can be purchased for as little as $15 per 1,000 square feet.

For a grass runway, regular maintenance is required to keep it in good condition. This includes mowing the grass, trimming the edges, and removing any debris or obstructions. If you're not comfortable performing these tasks yourself, hiring a professional contractor to maintain the runway can be an additional expense.

When planning the construction of an airport runway, it's essential to consider the performance capabilities of your aircraft and choose a surface material that can accommodate them. Additionally, make sure to comply with any relevant state and county regulations, as well as Federal Aviation Administration (FAA) guidelines, to ensure a safe and legal runway.

Examples of Private Runway Construction Costs

To provide a more concrete understanding, let's look at some examples of private runway construction costs:

• A 3,000-foot by 75-foot grass landing strip in South Carolina, built by veteran aviator Glen Gleason, required several months of work. The process included knocking down trees with a bulldozer, tiling and covering a ditch, and choosing the right type of grass.
• Jim Adams, a farmer, businessman, and pilot, constructed a 2,300-foot runway in North Carolina, which he later extended to 3,600 feet to accommodate a twin Comanche aircraft. He used a tractor and a box blade for levelling the land and seeded the runway with Bermuda grass.
• Jimmy Dean, a retired airline pilot, built an airfield in North Carolina measuring 2,400 feet by 150 feet. He cut down trees, removed stumps, and seeded the runway with Bermuda grass. He also purchased a tractor, a six-foot bush hog for rougher cutting, and a six-foot finishing mower for maintenance.

Understand regulations

Understanding the regulations that need to be complied with is a crucial step in building an airport runway. Here are the key regulatory considerations:

Federal Aviation Administration (FAA) Regulations

The FAA has specific rules and guidelines that must be followed to ensure the safety of pilots and people on the ground. These requirements include:

• The runway must be at least 500 feet long and 50 feet wide.
• A clear approach and departure path must be maintained for pilots.
• The runway must have proper markings and lighting.
• Adequate signage indicating the presence of a private airstrip is necessary.
• The private airstrip cannot be used for commercial purposes.

It is important to contact the FAA directly if you are unsure whether your proposed runway meets their requirements.

Local Zoning Regulations

In addition to FAA regulations, local zoning regulations must also be considered. These may include:

• Obtaining building permits or specific zoning approvals before construction can begin.
• Complying with local noise statutes, overflight rules, and environmental impact assessments.
• Addressing any concerns or complaints from neighbouring residents regarding aircraft noise.

State and Federal Regulations

When building a private airport, it is important to comply with state and federal regulations in addition to local laws and ordinances. This includes:

• Submitting basic location information and a schematic to the FAA to ensure your runway does not produce traffic conflicts with nearby airports or airspace obstacles.
• Complying with Part 157 of the Federal Aviation Regulations, which requires providing information on the construction, alteration, activation, and deactivation of civil or joint-use facilities.
• Notifying your state's aviation agency and complying with their requirements.

Insurance Requirements

Insurance requirements and risk factors should also be considered when building a private runway. Insurers may require paved runways for larger aircraft and will assess the frequency of aircraft operations and the maintenance of the field. It is important to disclose plans to operate from private airstrips to your insurer to ensure proper underwriting.

Neighbour Relations

While not a formal regulation, maintaining good relationships with neighbours is crucial to the success of your private runway. This includes being considerate of noise levels, offering free rides, and addressing any concerns they may have. Proactive community outreach can help streamline the approval process and reduce potential opposition to your project.

Prepare the site

Once the design is finalised, the construction site must be prepared. This involves several steps to ensure the land is ready for the runway to be built. Firstly, the area must be cleared, and all vegetation removed. Any trees or stumps will need to be removed, and this may involve using a bulldozer or other heavy machinery. The ground will then need to be levelled, and any necessary excavation or filling carried out to achieve the desired runway elevation and slope. This may involve grading the land, which means correcting any bumps and dips by flattening and filling in the area with dirt.

The next step is to install any required drainage features to facilitate water runoff. This is an important step to prevent water buildup on the runway, which could be dangerous for aircraft. If the runway is being built on low-lying ground, near ponds or rivers, drainage will be particularly important. Pumps, culverts, and ditches may be needed to manage water runoff.

With the ground level and clear, the next step is to lay the necessary infrastructure. This includes lighting, signage, and safety features. Lighting is crucial, especially for runways that will be used at night. Signs will be needed to indicate the presence of the runway and any relevant instructions or warnings. Safety features could include runway edge lights, which provide a visual indication of the runway boundary, and stopways, which are paved areas at the end of the runway that provide extra space for an aircraft to stop in the event of an overrun during takeoff or landing.

Finally, with the site cleared, levelled, and equipped with the necessary infrastructure, the ground will need to be compacted. This is done to provide a stable foundation for the runway structure. This step is crucial to ensure the runway can withstand the weight of aircraft and heavy traffic without degrading over time.

Frequently asked questions