Bolt-Torquing Technology Further Tightens Airfield Safety at Atlanta Int’l

Turning a wrench has gone digital for airfield crews at Hartsfield-Jackson Atlanta International Airport (ATL), at least when it comes to maintaining the lights along runways, taxiways and other critical pavement. For the past three years, they have been using a computerized bolt-torquing system that saves time and money while also making the airfield safer.

Meticulous maintenance is crucial for smooth operations at the world’s busiest airport, right down to the single turn of an individual bolt. In all, crews maintain 12,000 airfield light fixtures, which equates to a whopping 72,000 bolts. Previously, ATL relied on paper logs for documenting the location and corresponding torque value of each bolt, which made it virtually impossible to view historical data and analyze trends over time.

That all changed in 2021, when the airport invested in a new high-tech system from ADB SAFEGATE. The ALIS (Airside Location-based Inspection and Service) system digitally records and visualizes maintenance work using a dedicated mobile device connected to compatible torque wrenches used to tighten or loosen bolts on airfield lighting. The modern asset management tool streamlines work for crews by documenting all bolt torque values in its location-based program.

The Atlanta Department of Aviation awarded Brooks Berry Haynie and Associates an Airside On-Call contract to procure and implement the ALIS system at ATL. The firm also completes all routine bolt inspection and torquing under a contract to supplement and assist ATL’s Maintenance Department with electrical airfield work.

Increased Accuracy, Reduced Costs

Before the airport switched to the ALIS system, crews conducted bolt torquing inspections every 60 days, which cost ATL nearly $1 million per year. With the new equipment, the same work occurs in recurring 120-day cycles and an annual cost of closer to $250,000 to $300,000.

The airport was able to reduce its torquing frequency after evaluating three years of maintenance data. “If you want to extend that bolt torquing cycle, you have to demonstrate that the torque is remaining consistent, and this gives you the ability to be able to do that pretty efficiently,” comments Norma Click, ATL director of Airside/Landside, Planning and Development. “So, from that, we can show we don’t need to do bolt torquing as often, because the torque itself is stabilized.”

ATL’s computerized method also improves accuracy, as every aspect of the process is now measurable, eliminating inconsistencies and the need for manual logging, she adds.

Leveraging ADB SAFEGATE’s bolt-torquing technology has helped the airport minimize inconsistencies that arise from human factors, varying tools and changing weather conditions. Click notes that crewmembers working in the same elements now have an added level of efficiency and safety because the equipment indicates precisely where they need to focus.

The ALIS system and corresponding equipment also enhance accountability by recording the identity of who torques each bolt. The teams appreciate this added transparency, says Click.

Implementation and Training

To add the ALIS system, an airport provides ADB SAFEGATE with its geographical information system data, including fixture details, GPS locations and other asset information. Data is typically loaded into the new system within a day. Then, ADB SAFEGATE provides onsite training at the airport. “We go out with the crew that’s going to do torquing and make sure they know how to use the equipment,” says Byron Rosengarten, the company’s director of Aftermarket Sales and Service Americas.

ATL spent approximately $770,000 for the system initially, including four inspection cases and eight crew cases. The ATL Maintenance Department uses one inspection case and two crew cases; the rest are used by Brooks Berry Haynie & Associates. Both teams received training for the new system and tools. From ADB SAFEGATE, a standard implementation with the first-year subscription and two torque wrench kits costs approximately $100,000. After that, the subscription is $15,000 per year, which includes cloud data storage as well as support of the system.

Grant Holland of Brooks Berry Haynie & Associates says that ADB SAFEGATE worked with ATL and his firm to get the system dialed in and resolved all implementation issues in person and via remote tech support.

ADB SAFEGATE also worked with the airport to improve its dashboard and exporting options. The company’s Power BI dashboard allows users to export data from ALIS into a templated Excel format for review and analysis. Rosengarten notes that the Excel export template is usually well suited to users’ needs but can be customized for individual airports. Often, changes made for specific clients are rolled out to all ALIS users. In fact, the Excel template was initially developed for ATL, but ADB SAFEGATE later made it available to all customers.

Streamlining Processes

Technicians working at ATL can walk up to any fixture on the airfield, and the system instantly recognizes their location and displays data about that particular fixture on a mobile device. They can then begin torquing, and the system automatically records the torque value, ensuring each bolt is tightened to the specified level. This prevents over-torquing, which can lead to broken bolts, extra labor and potentially dangerous foreign object debris on the airfield.

The system also tracks how far a bolt rotates to reach the required torque. If a bolt needs to rotate significantly, that indicates it was loose and not providing adequate clamping force, which could also pose a safety risk. By checking torque values regularly, maintenance teams can determine if bolts remained tight or have loosened since the last check. This data allows airports to work with their FAA inspectors to potentially extend the time between required torquing.

At ATL, new intervals have reduced the labor hours needed to check and maintain its 72,000 airfield lighting bolts. “It’s obviously a massive undertaking to torque that many bolts,” Rosengarten comments. Since 2021, crews at ATL have torqued more than 750,000 bolts—and Rosengarten knows that with a quick glance at data in the ALIS system.

In addition to tracking what service is performed and who performed it, the system also provides alerts about upcoming maintenance or repairs. Whenever ATL maintenance personnel need to replace a light fixture, they have the ALIS equipment to tighten bolts back in place.

But not all of ATL’s airfield maintenance systems are so high-tech. It uses a decidedly low-tech system to clearly indicate which crew installed each bolt on any given light fixture. The ATL maintenance team uses red-coated bolts, while Brooks Berry Haynie & Associates uses blue-coated bolts.

Leading the Way

Because ATL was the first U.S. airport to deploy the ALIS system, ADB SAFEGATE worked closely with it to smooth out early issues. “In the beginning, there were some connectivity and range issues; however, with the updated and upgraded system, those problems have been resolved,” remarks Steve Woods, area manager with Brooks Berry Haynie & Associates.

The airport continues to benefit from the ability to update its assets within the ALIS program. “Being the busiest airport in the world, the airport is constantly growing and changing, so keeping up with and updating the system poses the biggest challenge,” comments Nick Bius, superintendent with Brooks Berry Haynie & Associates. “One of the greatest opportunities of the system is the ability to make these changes in real time.”

Taxiways recently added to ATL’s airfield are currently being added to the system dashboard.

Dallas Fort Worth International Airport (DFW), another ALIS customer, uses the system to help manage contractors working on airfield projects. Previously, crews did not always document bolt torque information when installing light fixtures on runways, taxiways and aprons. Now, DFW requires contractors to use a wrench that is compatible with ALIS to properly torque all bolts, and associated information is automatically recorded.

Using the ALIS dashboard, the airport can also verify work performed by outside contractors. The dashboard provides a detailed view of each fixture’s status, including how many have been properly torqued out of the total number for a project—giving the airport a real-time glimpse of each contractor’s progress. This allows ATL to address issues before the final project sign-off.

Continuous Improvement

Technology within the wrenches themselves has improved since ALIS was initially added at ATL in 2021. Previously, the wrenches had to connect to a power-train control module, which was wireless but required power from a truck to function. The power-train control module would then connect to an iPad, which connected via Bluetooth to technicians’ phones. Wrenches therefore needed to stay close to a power-train control module, and loss of connection was common.

ADB SAFEGATE has since integrated Bluetooth chips directly into the wrenches, eliminating the need for a power-train control module. The wrenches pair directly with technicians’ phones via Bluetooth and can work offline without a cellular connection. This simplifies the system, reduces the risk of losing connections and removes the need to keep a truck nearby. ADB SAFEGATE has upgraded all the wrenches at U.S. airports to this new system, retrofitting existing tools to ensure everyone benefits from the streamlined setup, says Rosengarten.

Looking ahead, the company is beginning to deploy smart fixtures at some airports. These fixtures have advanced capabilities, such as detecting LED outages, verifying alignment and monitoring temperature and pressure. The pressure readings are particularly valuable, as they can help identify leaks in sealed fixtures. Data from the smart fixtures is integrated into ALIS, where users can receive alerts about specific issues, such as fixture leaks. This allows proactive maintenance and early replacement of faulty components before more significant, costlier issues arise.

Beyond Bolts

Although it was initially developed for bolt torquing, the ALIS system has evolved to track and record maintenance for other assets, such as regulators and airfield signage. Essentially, it acts as an electronic logbook that allows airports to review and analyze data over time. Maintenance teams can use the system to schedule replacements or set up preventive maintenance tasks, such as checking signage for faded panels once or twice a year.

Similarly, ALIS can document and help manage fixed assets. For instance, users can log the location and details of each manhole, including photos. When field technicians need to access a manhole, they have all necessary information readily available.

In addition to providing specific torque values for each bolt, the system records the identity of workers who perform the torquing.

Integration With Other Systems

Rosengarten notes that the ALIS system is not meant to replace or compete with airport-wide asset management systems such as Maximo or Cityworks. Instead, it is designed to complement them by focusing specifically on airside maintenance.

Because ALIS has an open application programming interface, it can integrate with other asset management systems. This is the case at Harry Reid International Airport (LAS) in Las Vegas, which uses ALIS and Maximo in concert. “We connected the systems together, so when they create a work order in Maximo, it automatically creates a work order in ALIS,” Rosengarten explains. When technicians at LAS perform and complete airfield work in ALIS, it then updates and closes the work orders in Maximo. This allows office staff to continue using Maximo, while technicians use ALIS out on the airfield.

Advice for Others

Woods describes the ALIS system as an invaluable tool but emphasizes the importance of proper planning for effective implementation and use. “For an airport the size of [ATL], it can take years of surveying and planning to have the proper information to input into the database for the system to work properly and identify assets correctly,” he says. “Having the ability for recordkeeping and all members of an airport staff to see the same information in real-time from any location is one of the most valuable functions of the ALIS system.”

Rosengarten highlights the safety implications of bolt-torquing technology. “That should always be No. 1 when you’re working with airplanes and on an airfield—safety for the team and the passengers that are onboard these planes,” he stresses. “So first and foremost, you’re ensuring that you’re complying with all safety regulations.”

Moreover, complying with FAA requirements helps avoid operational disruptions, such as runway closures. Rosengarten notes that airports can use data from ALIS to proactively evaluate their maintenance schedules with FAA inspectors.

Click understands that other airports, depending on their size and available funding, may be reluctant to make the initial investment for bolt-torquing technology that ATL made. “But I think just in the efficiency, the accountability, the tracking and the historical information—I think you’re definitely rewarded in the long run,” she remarks. “We have zero regrets.”

Airside Updates

Like usual, ATL has several improvement projects in the works. It is currently in the midst of a $1.4 billion project to widen Concourse D using modular design and construction. The massive undertaking will expand the concourse by 60% to increase capacity and accommodate larger airplanes. (For more details, see the July/August 2024 issue of Airport Improvement.)

In 2026, the airport will replace its longest runway (9L-27R, measuring 12,390 feet) and several associated taxiways. The project will update select areas to meet current FAA standards, which includes removing and changing the geometry of certain taxiways.

All these projects, and more in the future, will benefit from the bolt-torquing system ATL already has in place.