A Strategic Overhaul at France’s Second-Largest Airport
At the request of Groupe ADP, Colas took part in a major infrastructure project: the renovation of Runway 3 at Paris-Orly Airport, a strategic asset for France’s air traffic. Originally built just after WWII and extended in 1959, the runway required a full upgrade to meet current safety and performance standards.
Launched in late July 2019, the project involved:
- Complete reconstruction of the western two-thirds of the runway,
- Resurfacing of the remaining third,
- Upgrading all aeronautical systems (lighting, cabling, networks, etc.).
The operation was doubly complex:
- It coincided with the strengthening of the aircraft bridge over the RN7 highway,
- And overlapped with the tunneling of the Grand Paris Express, 30 meters below the surface.
A High-Stakes Project with Tight Deadlines
Orly Airport is a key hub, handling 33 million passengers annually, 627 daily flights, and 30 airlines. Extended closures were not an option. The entire project was completed in just 14 weeks, a true logistical feat.
At peak activity:
- Between 650 and 800 workers were mobilized,
- Over 150 heavy machines operated simultaneously,
- Crews worked around the clock to meet deadlines.
Despite the scale of the works, only 10% of scheduled flights were impacted during the operation, thanks to precise phasing led by Groupe ADP engineering and Colas teams.
Circular Economy: 235,000 Tons of Concrete Recycled On-Site
Beyond technical excellence, this project followed a model circular economy approach. The goal: reuse 100% of the 185,000 m² of concrete slabs from the old runway.
Key figures:
- Average thickness: 40 cm → Total: 235,000 tons,
- 125,000 tons processed to rebuild the new runway,
- 49,000 tons reused as drainage material for trenches,
- Remaining quantities used for network works or other projects.
To minimize transportation impact, three production units were installed directly on-site:
- Crushing of old slabs,
- Processing and production of new concrete,
- Final asphalt manufacturing.
This strategy eliminated:
- 13,000 semi-trailer trips,
- 6,500 round trips for removal and 6,500 for new materials.
A Model of Sustainable Airport Construction
With this project, Colas showcases its expertise in managing complex airport works with high technical and environmental stakes. Multi-stakeholder coordination, reduced logistical impact, and on-site recycling make this a benchmark for sustainable, high-performance airport infrastructure.
