German high-pressure water jet systems manufacturer Weigel has recently completed over 40,000m² of rubber removal services, at the Moron Air Base (Moron AB) runway.
The base is located in southern Spain, close to the city of Seville, and has became a key pillar in the air-bridge for airlift and fighter deployments in support of several operations, as well as a crucial refuelling support base (it was the largest tanker base during the Kosovan war in 1999).
Moron's massive flight line, in-ground aircraft refuelling system, long runway and prime location on the Iberian peninsula made the base is a vital link in many operations moving east from the US. The particularly long and wide runway is frequently used by heavy aircraft like the C-5, the C-17 and KC-135 and KC-10 tankers. Moron AB is also the home of the Spanish Air Force Ala 11 squadrons, with daily movements of Eurofighter Typhoons.
In 1984, Moron became a NASA space shuttle transoceanic abort landing (TAL) site in support of the space shuttle program. Such a responsibility imposes several special requirements with regard to navigation and landing aids, personnel, and infrastructure, including the runway.
Rubber deposits were already quite significant on both touch-down zones, as the previous rubber removal intervention took place more than three years previously, and both runway ends are frequently used for landings. The typical elliptical shapes of rubber marks were covering an asphalt area and also the concrete ends, with an extension of around 300m, almost up to the threshold lines.
The rubber removal operations were performed every day, during the periods with less aircraft movements, to minimise interruptions. One of the most recent TrackJet models, the TJ-24 with high-capacity vacuum suction system, successfully achieved the demanding degree of removal USAFE demanded (up to 90%) without damaging the surface, and allowing an average speed of 700m²/h, and even more on concrete areas.
Using an exclusive computerised control system, the TrackJet removed rubber on two different pavement types, with homogeneous results, without damaging the surface, the paint marks, the sealings or the arresting system.
The high temperatures (over 35°C) registered during the day were not a problem for the equipment, as it is designed to work in even tougher environments, like the Middle East or Africa, where Weigel already operates several systems.
496th Air Base Squadron airfield manager, MSgt Jonathan Sollisch, responsible for runway pavement matters at Moron, followed closely the evolution and progress of the mission, confirming his approval at the final inspection: "In 17 years of experience, I must confess I've never seen such an efficient removal method. Perfect!" he said.
Although concerned with the friction reduction that the rubber deposits cause, MSgt Sollisch was also concerned about potential damages to the pavement. He was pleased to notice our equipment's capacity to control the water jets according to the thickness of the rubber layer prevented damage. “Approved with no doubt,” confirmed the airfield manager.
The positive results were especially impressive on concrete, not due to a higher removal rate, or to a lower rubber accumulation layer, but most of all, because the colour contrast between the black rubber and the grey concrete was even more evident there.
Ruben Figueiredo, from Weigel/TradeTarget, who oversaw the project, explained: "After almost 60 consecutive operating hours, we left Moron without one single failure and with the customer pleased. That's our goal for all missions, on asphalt or concrete pavements, on military or commercial airfields: removing rubber deposits or paint marks."
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