March 21, 2025
Air travel plays a critical role in both personal and commercial transportation with the Federal Aviation Administration (FAA) managing an average of 45,000 flights per day.1 To support such a high volume of air traffic, runways must remain in optimal condition. But heavy use, harsh weather conditions, and natural wear and tear can lead to surface deterioration such as spalls, cracks, and structural damage.
To ensure safety, minimize disruptions, and maintain efficiency, routine runway maintenance and repair are essential. We take a closer look at airport runway repair and crack-filling processes, along with a review of some specialized dispensing equipment we recommend.
Dowel Bar Placement in Runways
Dowel bars play a crucial role in airport runway concrete repair by facilitating load transfer between adjacent slabs to ensure both structural integrity and longevity. The damaged section of the runway is cut out and removed. Dowel bars are evenly spaced and inserted into holes in the concrete to anchor the new section to the existing one. Epoxy is injected into the remaining space in the holes to secure the dowel bars as well as mitigate vibration. This same technique can be used to expand airport runways.
While some contractors rely on cartridge guns to dispense the epoxy, this method is inefficient and can lead to excessive waste. Instead, we suggest a different dispensing solution to optimize product usage and minimize application time.
What We Recommend...
This dispensing system is specially designed for industrial applications involving two-part epoxies. Compared to cartridge guns that can only dispense a small amount of epoxy at a time, this system has a continuous flow rate of up to 0.8 gallons per minute and the capability for up to 20 cycles per minute. It also features an adjustable metered shot system for precise and accurate dispensing of the epoxy.
Few machines on the market offer these same advanced capabilities, but the AST RMP-624 is the only system that allows materials to be added to the hopper without interrupting the workflow. Other systems require the workers to stop operations to replace the pail each time the material runs out. In contrast, the RMP-624 system's gravity-feed technology enables seamless and uninterrupted operations to maximize productivity. The system can also be configured to meet unique specifications as needed.
Altogether, these capabilities make the AST RMP-624 arguably the most consistent and efficient dispensing solution for such a large-scale application like concrete airport runway repair.
Filling Expansion Joints & Saw Cut Joints in Runways
Expansion joints and saw cut joints in runways are strategically used to accommodate concrete movement of up to 2%, but they must be properly filled to maintain a smooth and even surface for the planes. Because of their resistance to jet fuel and great flexibility, silicones and urethanes are commonly used to fill these gaps while ensuring long-term durability.
To dispense these materials accurately and efficiently, our team suggests two different pieces of equipment depending on your needs.
Recommendation for Bulk Applications
AST SP-55 Expansion Joint Filling System
For high-volume joint filling in rapid runway repair applications, this machine is an optimal solution. It is specifically engineered to dispense single-component silicones and urethanes from 55-gallon drums for high-output workflow.
Compared to similar equipment, the SP-55 has several key advantages. It is equipped with external check valves for quick and easy access when troubleshooting issues with crud buildup. In contrast, other systems require the disassembly and reassembly of the machine to reach these components. This unnecessary downtime can significantly decrease productivity.
Another key advantage of the system is its precision guide to ensure proper alignment of the taper with the pump. This design helps hold the pressure seal in place so the system can consistently build and sustain pressure. Those machines without this feature are more susceptible to misalignment. As a result, the pressure seal has a shorter service life and requires frequent replacements.
By streamlining maintenance and minimizing interruptions, the AST SP-55 ensures a more efficient and reliable joint filling process for runway and airstrip repairs.
Recommendation for Smaller Applications
This system is essentially a lower-output version of the AST SP-55 pump. Instead of using 55-gallon drums, it is made for use with 5-gallon pails. While designed for smaller volume applications, it retains the same key features as its larger counterpart.
It is equipped with external check valves for fast and simplified maintenance that can minimize downtime and improve overall efficiency. It also features a precision guide to ensure proper alignment and secure the pressure seal. This specific design enhancement can prevent misalignment-related wear and tear and significantly improve the service life of the machine. Overall, the SP-5 is a rugged and reliable piece of equipment for airport runway joint filling applications.
Get the Equipment You Need
With growing air traffic numbers, efficient and rapid runway repairs are all the more imperative. If you want to learn more about one of these pieces of equipment, contact us and speak with one of our dispensing experts. We may also be able to configure the machine to better meet your specific needs.
Sources:
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Federal Aviation Administration (2024). Air Traffic By The Numbers
