Manchester Airport

Project overview

Manchester Airport operates under extremely demanding aviation trafficking conditions. Progressive surface fatigue within a critical airside access route resulted in cracking, deformation and increasing maintenance intervention. Previous asphalt solutions installed without the use of a geosynthetic reinforcement had failed prematurely due to reflective cracking and fatigue under heavy operational loading. Protar Surfacing planed out a total of 120mm of failed concrete, removing the distressed material in full prior to installation of Glasstex P100/200 reinforcement within the new asphalt construction. The geosynthetic reinforcement was incorporated to enhance tensile capacity, improve stress distribution and mitigate reflective cracking under heavy operational loading.

Project challenges

Heavy trafficking from airside and service vehicles

High shear stresses generated by slow-moving, heavily loaded ground support equipment

Previous asphalt solutions installed without the use of a geosynthetic reinforcement had failed prematurely due to reflective cracking and fatigue

Progressive surface deformation and cracking leading to increased maintenance intervention

Requirement to work within a live operational airport environment

Need to minimise disruption while delivering a long-term, structurally robust solution

The solution

Following removal of the failed surface by Protar Surfacing, the underlying structure was assessed and prepared, with regulating layers installed where required to ensure a stable and uniform foundation. Duropave then installed Tensar Glasstex P100/200 reinforcement within the asphalt construction to create a high-strength composite pavement structure capable of resisting tensile stresses and shear forces generated by heavy operational loading.

Key benefits delivered

Enhanced structural strength

Improved crack control

Optimised load distribution

Extended service life

Reduced whole-life cost and carbon impact