Preventive Maintenance at General Aviation Airports Volume 2: Guidebook (2015)

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A I R P O R T C O O P E R A T I V E R E S E A R C H P R O G R A M ACRP REPORT 138 TRANSPORTAT ION RESEARCH BOARD WASHINGTON, D.C. 2015 www.TRB.org Research sponsored by the Federal Aviation Administration Subscriber Categories Aviation • Maintenance and Preservation Preventive Maintenance at General Aviation Airports Volume 2: Guidebook David C. Ploeger and Robert B. Chapman Delta airport Consultants, inC. Albuquerque, NM, and Atlanta, GA David G. Peshkin applieD pavement teChnology, inC. Urbana, IL Donna J. Speidel sightline, lC Culpeper, VA

AIRPORT COOPERATIVE RESEARCH PROGRAM Airports are vital national resources. They serve a key role in trans­ portation of people and goods and in regional, national, and inter­ national commerce. They are where the nation’s aviation system connects with other modes of transportation and where federal respon­ sibility for managing and regulating air traffic operations intersects with the role of state and local governments that own and operate most airports. Research is necessary to solve common operating problems, to adapt appropriate new technologies from other industries, and to introduce innovations into the airport industry. The Airport Coopera­ tive Research Program (ACRP) serves as one of the principal means by which the airport industry can develop innovative near­term solutions to meet demands placed on it. The need for ACRP was identified in TRB Special Report 272: Airport Research Needs: Cooperative Solutions in 2003, based on a study spon­ sored by the Federal Aviation Administration (FAA). The ACRP carries out applied research on problems that are shared by airport operating agencies and are not being adequately addressed by existing federal research programs. It is modeled after the successful National Coopera­ tive Highway Research Program and Transit Cooperative Research Pro­ gram. The ACRP undertakes research and other technical activities in a variety of airport subject areas, including design, construction, mainte­ nance, operations, safety, security, policy, planning, human resources, and administration. The ACRP provides a forum where airport opera­ tors can cooperatively address common operational problems. The ACRP was authorized in December 2003 as part of the Vision 100­Century of Aviation Reauthorization Act. The primary participants in the ACRP are (1) an independent governing board, the ACRP Oversight Committee (AOC), appointed by the Secretary of the U.S. Department of Transportation with representation from airport operating agencies, other stakeholders, and relevant industry organizations such as the Airports Council International­North America (ACI­NA), the American Associa­ tion of Airport Executives (AAAE), the National Association of State Aviation Officials (NASAO), Airlines for America (A4A), and the Airport Consultants Council (ACC) as vital links to the airport community; (2) the TRB as program manager and secretariat for the governing board; and (3) the FAA as program sponsor. In October 2005, the FAA executed a contract with the National Academies formally initiating the program. The ACRP benefits from the cooperation and participation of airport professionals, air carriers, shippers, state and local government officials, equipment and service suppliers, other airport users, and research orga­ nizations. Each of these participants has different interests and respon­ sibilities, and each is an integral part of this cooperative research effort. Research problem statements for the ACRP are solicited periodically but may be submitted to the TRB by anyone at any time. It is the responsibility of the AOC to formulate the research program by iden­ tifying the highest priority projects and defining funding levels and expected products. Once selected, each ACRP project is assigned to an expert panel, appointed by the TRB. Panels include experienced practitioners and research specialists; heavy emphasis is placed on including airport pro­ fessionals, the intended users of the research products. The panels pre­ pare project statements (requests for proposals), select contractors, and provide technical guidance and counsel throughout the life of the project. The process for developing research problem statements and selecting research agencies has been used by TRB in managing cooper­ ative research programs since 1962. As in other TRB activities, ACRP project panels serve voluntarily without compensation. Primary emphasis is placed on disseminating ACRP results to the intended end­users of the research: airport operating agencies, service providers, and suppliers. The ACRP produces a series of research reports for use by airport operators, local agencies, the FAA, and other interested parties, and industry associations may arrange for work­ shops, training aids, field visits, and other activities to ensure that results are implemented by airport­industry practitioners. ACRP REPORT 138, VOLUME 2 Project 10­18 ISSN 1935­9802 ISBN 978­0­309­30875­5 Library of Congress Control Number 2015941287 © 2015 National Academy of Sciences. All rights reserved. COPYRIGHT INFORMATION Authors herein are responsible for the authenticity of their materials and for obtaining written permissions from publishers or persons who own the copyright to any previously published or copyrighted material used herein. Cooperative Research Programs (CRP) grants permission to reproduce material in this publication for classroom and not­for­profit purposes. Permission is given with the understanding that none of the material will be used to imply TRB or FAA endorsement of a particular product, method, or practice. It is expected that those reproducing the material in this document for educational and not­for­profit uses will give appropriate acknowledgment of the source of any reprinted or reproduced material. For other uses of the material, request permission from CRP. NOTICE The project that is the subject of this report was a part of the Airport Cooperative Research Program, conducted by the Transportation Research Board with the approval of the Governing Board of the National Research Council. The members of the technical panel selected to monitor this project and to review this report were chosen for their special competencies and with regard for appropriate balance. The report was reviewed by the technical panel and accepted for publication according to procedures established and overseen by the Transportation Research Board and approved by the Governing Board of the National Research Council. The opinions and conclusions expressed or implied in this report are those of the researchers who performed the research and are not necessarily those of the Transportation Research Board, the National Research Council, or the program sponsors. The Transportation Research Board of the National Academies, the National Research Council, and the sponsors of the Airport Cooperative Research Program do not endorse products or manufacturers. Trade or manufacturers’ names appear herein solely because they are considered essential to the object of the report. Cover photo by Delta Airport Consultants, Inc., of Columbiana County Airport (East Liver pool, OH) Published reports of the AIRPORT COOPERATIVE RESEARCH PROGRAM are available from: Transportation Research Board Business Office 500 Fifth Street, NW Washington, DC 20001 and can be ordered through the Internet at http://www.national­academies.org/trb/bookstore Printed in the United States of America

The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. Upon the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Ralph J. Cicerone is president of the National Academy of Sciences. The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. C. D. Mote, Jr., is president of the National Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Victor J. Dzau is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Ralph J. Cicerone and Dr. C. D. Mote, Jr., are chair and vice chair, respectively, of the National Research Council. The Transportation Research Board is one of six major divisions of the National Research Council. The mission of the Transporta- tion Research Board is to provide leadership in transportation innovation and progress through research and information exchange, conducted within a setting that is objective, interdisciplinary, and multimodal. The Board’s varied activities annually engage about 7,000 engineers, scientists, and other transportation researchers and practitioners from the public and private sectors and academia, all of whom contribute their expertise in the public interest. The program is supported by state transportation departments, federal agencies including the component administrations of the U.S. Department of Transportation, and other organizations and individu- als interested in the development of transportation. www.TRB.org www.national-academies.org

C O O P E R A T I V E R E S E A R C H P R O G R A M S CRP STAFF FOR ACRP REPORT 138, VOLUME 2 Christopher W. Jenks, Director, Cooperative Research Programs Michael R. Salamone, ACRP Manager Marci A. Greenberger, Senior Program Officer Joseph J. Brown-Snell, Program Associate Eileen P. Delaney, Director of Publications Doug English, Editor ACRP PROJECT 10-18 PANEL Field of Operations Kerry L. Ahearn, Boulder City Municipal Airport, Boulder City, NV (Chair) Qingbin Cui, University of Maryland, College Park, MD Charles T. “Skip” Miller, Louisville Regional Airport Authority, Louisville, KY William J. Potter, Emerald Airport Consulting, LLC, Santa Rosa Beach, FL Casey W. Ries, Gerald R. Ford International Airport, Grand Rapids, MI Gary Shafer, Southern Illinois Airport, Carbondale, IL Randy Moseng, FAA Liaison James W. Bryant, Jr., TRB Liaison

ACRP Report 138: Preventive Maintenance at General Aviation Airports is published as a two­volume set. Volume 1 is a primer for airport governing­ and policy­board members on the importance and value of a preventive maintenance program. Volume 2 is a guidebook for airport managers, maintenance managers, and all line personnel on how to plan, priori­ tize, and conduct preventive maintenance for physical infrastructure assets. This Volume 2 Guidebook assists airport and maintenance management and all staff responsible for maintenance and repair of the airport’s physical infrastructure assets in understanding preventive maintenance (PM) programs. It includes guidance on conduct­ ing PM for typical airport physical infrastructure assets. Volume 2 also contains a CD­ROM that includes system checklists that airport staff can customize for their use, as well as a PowerPoint presentation that can be shown to governing boards or communities on the importance of budgeting for preventive maintenance. General aviation airports of all sizes are an integral part of the National Aviation System. Many of these airports have aging facilities, changing facility demands to accommodate the changes in the general aviation industry, and diminishing revenue sources. These trends coupled with limited staff and budgets have made it difficult to properly maintain the facili­ ties beyond responding to immediate needs. Airport management responds well to those needs, but these efforts leave little time for true maintenance planning. PM programs can be effective at ensuring that physical assets operate reliably and effi­ ciently. However, preventive maintenance is not always funded. Delta Airport Consul­ tants, Inc., as part of ACRP Project 10­18, conducted research on the benefits and value of an airport preventive maintenance program, as well on the typical physical infrastructure assets at airports and the considerations for developing a preventive maintenance pro­ gram for those assets. Airport policy­ and governing­board members will find the primer informative on the need and the value that a preventive maintenance program provides. Airport management and their staff will find that the guidebook illustrates how to set up a preventive maintenance program and provides specific guidance for specific assets. The primer and guidebook will be useful for general aviation airports of all sizes. F O R E W O R D By Marci A. Greenberger Staff Officer Transportation Research Board

Note: Photographs, figures, and tables in this report may have been converted from color to grayscale for printing. The electronic version of the report (posted on the web at www.trb.org) retains the color versions. 1 Chapter 1 Introduction 1 1.1 Background 2 1.2 Purpose of Guidebook 2 1.3 How to Use the Guidebook 4 Chapter 2 Preventive Maintenance—An Overview 4 2.1 Introduction 4 2.2 What Is Preventive Maintenance? 5 2.3 Why Is Preventive Maintenance Important? 7 2.4 What Entities Are Involved with Preventive Maintenance? 9 2.5 Principles of a Preventive Maintenance Program 10 Chapter 3 An Airport Preventive Maintenance Program 10 3.1 Introduction 10 3.2 Facility Condition Assessment 10 3.3 Life­Cycle Considerations 12 3.4 Budgeting 13 3.5 Organizational Structure and Staffing 14 3.6 Prioritizing Preventive Maintenance 14 3.7 Using Contracts and Other Agencies 15 3.8 Tools and Equipment 15 3.9 Work Orders and Recordkeeping 17 Chapter 4 Preventive Maintenance Procedures 17 4.1 Introduction 17 4.2 Safety Considerations 19 4.3 Airport Inspections 26 4.4 Infrastructure Checklists 102 Chapter 5 Summary 102 5.1 Key Points 103 5.2 Where to Go for Help 104 Appendix A Airports/States Providing Assistance 105 Appendix B Bibliography 108 Appendix C Sample Airport Documents 112 Appendix D Pavement Treatments C O N T E N T S