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Auckland Airport, the bustling aviation hub of New Zealand, is making waves in the industry with its groundbreaking approach to infrastructure development. In an ambitious endeavour to expand its airfield and accommodate a new combined domestic and international terminal, the airport is recycling its runway and revolutionizing construction practices while minimizing waste and environmental impact. This progressive move showcases Auckland Airport’s commitment to sustainability and underscores its dedication to efficient operations and enhanced passenger experiences.

Under the visionary leadership of André Lovatt, Chief Infrastructure Officer at Auckland Airport, the project aims to repurpose existing materials on-site, diverting at least 70% of construction waste. By reusing 108,000 tonnes of concrete from the runway touchdown zones, the airport is reducing waste and eliminating the need for approximately 6,000 truck trips on Auckland’s roads. This innovative approach reflects Auckland Airport’s forward-thinking mindset and determination to lead the way in sustainable aviation infrastructure.

The recycled concrete will be crushed and repurposed as a backfill for a colossal 250,000 square meters of a new airfield west of the international terminal. The decision to reuse the concrete on-site aligns with the airport’s objective to create a robust and stable base capable of supporting fully laden aircraft. Lovatt explains, “We’ve been undergoing pavement renewals across our runway and taxiways, and rather than disposing of the old pavement offsite, we’ve been setting it aside. The old pavement is now being crushed on-site for use in the airfield expansion, scheduled for completion between now and mid-2025.”

This ambitious project, spanning over an area equivalent to 23 rugby fields, marks the most significant airfield expansion in Auckland Airport’s history. It plays a crucial role in developing a new integrated terminal where the domestic and international terminals will merge seamlessly. Lovatt states, “We need to create a new area for aircraft parking, with a large part of the airfield becoming a construction site for developing the newly integrated terminal. This requires additional space for apron and airfield operations, impacting the current temporary aircraft parking area.”

The airfield expansion project incorporates the addition of extra taxiways and seven remote stands for aircraft that have layovers lasting several hours before their next departure. Five of these stands will be equipped with in-ground jet fuel reticulation and other essential services. Additionally, the expansion project will eventually connect to a planned cargo precinct and, in the more distant future, a second runway. The revival of this project, which had been put on hold during the onset of the pandemic, is now a moment of excitement for Auckland Airport, as it paves the way for the construction of the new terminal and ensures minimal disruption to airline operations.

The engineering behind the airfield expansion requires a base approximately 1.5 meters deep, capable of withstanding the weight of A380s, which can reach 280 tonnes. By repurposing existing materials, Auckland Airport exemplifies efficiency and responsible construction waste management. The production of cement, a key ingredient in concrete, contributes to approximately 8% of global carbon emissions, and construction waste constitutes a significant portion of the waste stream. Auckland Airport’s goal of diverting at least 70% of construction waste from landfill aligns with its broader commitment to sustainability.

Lovatt emphasizes the airport’s sustainability targets, stating, “New ‘green concrete’ technologies are emerging that will help reduce emissions in the construction industry. However, an immediate action we can take is to maximize the use of existing materials beyond their original purpose. We have ambitious goals, including reaching net zero direct emissions by 2030, and we actively seek opportunities for waste minimization and further emissions reduction.”

The decision to repurpose the concrete as engineered backfill will save approximately 3,900 disposal trips and 2,400 trips of imported fill material. These numbers reflect the significant environmental impact of Auckland Airport’s innovative approach, setting a remarkable example for sustainable construction practices within the aviation industry.

As Auckland Airport undertakes its remarkable airfield expansion, the $3.9 billion development program encompasses various aspects, including the 250,000-square-meter airfield expansion. The scale of the project is staggering, involving the movement of 750,000 cubic meters of earth and utilizing 350,000 tonnes of aggregate for pavement construction. The taxiways and remote stands will adhere to Code F standards, accommodating the largest operating aircraft, both present and future, with wingspans exceeding 65 meters.

Auckland Airport’s recycling of its runway and subsequent airfield expansion represents a pivotal moment in the aviation industry’s sustainability journey. By repurposing materials on-site, the airport reduces waste, minimises environmental impact, and showcases its dedication to responsible construction practices. This ambitious project is a testament to Auckland Airport’s vision for greener, more efficient, and passenger-friendly aviation infrastructure.