Airport Loses $800,000 Gift: Concrete Too Weak for 767

COSTA MESA —  The Federal Aviation Administration has denied $800,000 of a $2.5-million grant sought by John Wayne Airport because part of the new terminal’s concrete apron failed to meet U.S. strength standards.

Assistant Airport Manager Jan Mittermeier on Friday described the FAA decision as only a minor problem. “We think that with more testing we may be able to convince them to restore the funds later on,” she said.

Airport officials previously disclosed the apron problem, which resulted when concrete that passed initial chemical tests while it was being poured was later found to be too weak after it dried.

The FAA standard, officials said, required the concrete to be usable over many years for aircraft as heavy as the Boeing 767, the largest expected to use the facility.

Mittermeier said that loss of the $800,000 in federal money would, if necessary, be covered by airport cash reserves.

The apron contractor is the firm of Ball, Ball and Brosamer, whose officials were unavailable for comment.

The FAA has previously approved airfield improvement grants to the county, but the total dollar amount was not immediately available late Friday. Still more money from the nation’s airport improvement fund, administered by the FAA, will be sought before the current John Wayne Airport project is finished.

Airport officials tried unsuccessfully to persuade the FAA to accept tests showing that the ground underneath the concrete is stronger than first thought, thus compensating for the concrete weakness. They argued that the ground and concrete could be seen as the same support system.

The strength test failure was not the first crisis affecting the apron. Part of the Tarmac had to be replaced when officials discovered that it was not level.

Nor is the $14-million apron project, which includes new fuel lines and other related work, the only construction item to perplex county officials. The airport improvement program has been plagued by design flaws, delays and cost overruns in its two-year history, although some portions have come in below budget.

Prime airport contractor Taylor Woodrow was recently fired from a garage contract and has sued the county.

The apron and $61-million passenger terminal are parts of a $310-million airport expansion that also includes freeway ramps, roads, parking garages, aircraft taxiways and car rental facilities.

The new terminal is scheduled to open Sept. 16, after an open house on Sept. 8.