KEWL Airport Master Plan

Located approximately 50 miles from downtown Chicago, the Elwood Logistics Airport development plans places it adjacent to logistics transfer centers for two major Class I railroads with connections to all major West Coast ports. The logistics campus has connections with Ocean Carriers, Railroads, Trucking Companies, Shippers, and Third-Party Logistics. 

An approximately 4.23 sq. mi. parcel of land in Jackson Township, Illinois has been secured east of the Village of Elwood center, east of IL Route 53. 

Primarily bordered to the west by an offset from South Coldwater Road, to the south by West Hoff Road, and to the east by Cherry Hill Road. At the western end of the site, the property is bordered to the north for a portion by South Mississippi Road. 

A survey of the site has shown that the entire parcel can support the construction of a dual-runway airport. 

The airport master plan includes the construction of two (2) parallel bi-directional runways, four (4) cargo terminal buildings with two separate ramp areas, three (3) transport category hangars for maintenance operations, a general aviation ramp area with six (6) hangar buildings each with eight (8) leasable hangars and capacity for up to 50 tie-down aircraft parking and one passenger terminal.

A survey of the site has shown that the entire parcel can support the construction, as shown in Figures below. The images depict the existing and future airport facilities, required facility identifications, description labels, imaginary surfaces, runway protection zones, runway safety areas and basic airport and runway data tables. It may be necessary to include the data tables on a separate sheet.

Currently, a fuel farm is planned for the space west of the hangar areas and emergency services and snow removal facilities are expected to be developed adjacent to the passenger terminal, but both are still in design and are not shown.  

The FAA has reserved the airport identifier as KEWL  for Elwood Logistics Airport. 

Surface Transportation Considerations

To determine the regional surface transportation network’s interaction with the airport, an Airport Master Plan examines the surface transportation network and proposes modifications and/or improvements to the existing system to accommodate an airport’s proposed development.

The Federal Aviation Administration’s “Airport Master Plans” Advisory Circular 150/5070-6B states that: “The regional roadway network, on-airport circulation roadways, and parking facilities are the principal components of the ground access system. The capacity and reliability of this system will determine the level of service provided to air travelers on the ground access segment of their trip.”

The Elwood Logistics Airport Master Plan will include two detailed surface transportation studies: an Access Justification Report (AJR) and an Airport Access Plan.

Access Justification Report

The AJR includes reviews the current interchange on Interstate 55 with Arsenal Road and includes assessing local roads including Illinois Route 50, W Manhattan Road, W Mississippi Road, W Hoff Road and others deemed necessary.  The AJR also studies the implications and logistics of crossing the Union Pacific and BNSF mainlines. Once complete, the AJR is subject to evaluation by the Illinois Department of Transportation - Division of Highways, and the Federal Highways Administration (FHWA).

The airport master plan includes the construction of two (2) parallel runways, four (4) cargo terminal buildings with two separate ramp areas, three (3) transport category hangars for maintenance operations, a general aviation ramp area with six (6) hangar buildings each with eight (8) leasable hangars and capacity for up to 50 tie-down aircraft parking and one passenger terminal. Currently, a fuel farm is planned for the space west of the hangar areas and emergency services and snow removal facilities are expected to be developed adjacent to the passenger terminal, but both of these are still in design.   

Description of Runways 

Runway 10L -28R

Heading True/Mag (deg):  10L - 101/104; 28R - 281/284

Length x Width (ft) 10,000 ft x 200 ft   

Elevation: 670 ft MSL

Highspeed Taxiways: 6

Runway 10L Approach: RNAV (GPS)

  Visibility Min: >.75 NM

  Glideslope: 3.00 deg

  Threshold Crossing Height: 52 ft. AGL

Runway 10L Approach: ILS or LOC

  Visibility Min: >0.5 NM

  Glideslope: 3.00 deg

  Threshold Crossing Height: 50 ft. AGL

Runway 28R Approach: RNAV (GPS)

  Visibility Min: >.75 NM

  Glideslope: 3.00 deg

  Threshold Crossing Height: 48 ft. AGL

Runway 28R Approach: ILS or LOC

  Visibility Min: >0.5 NM

  Glideslope: 3.00 deg

  Threshold Crossing Height: 46 ft. AGL

Runway End: 10R - 28L

Heading True/Mag (deg): 101/104

Length x Width (ft) 4,500 ft x 150 ft  

Elevation: 670 ft MSL      

Runway 10R Approach: RNAV (GPS)

  Visibility Min: >.75 NM

  Glideslope: 3.05 deg

  Threshold Crossing Height: 68 ft. AGL

Runway 28L Approach: RNAV (GPS)

  Visibility Min: >.75 NM

  Glideslope: 3.05 deg

  Threshold Crossing Height: 65 ft. AGL

Runway Safety Geometry

The Runway Safety Area (RSA) is a graded surface centered on a runway that is required to be free of all objects except for items such as runway navigational aids and landing systems or runway lighting (items that are required and are ‘fixed by function’). RSA geometry (width and length) depends on the runway design needs (based on Aircraft Approach Category (AAC) and Airplane Design Group (ADG) of the critical, and likely, operating aircraft) and the runway approach visibility minimums.

The Runway Protection Zone (RPZ) is used to enhance the safety of people and property on the ground surrounding a runway by limiting and/or restricting the construction of certain structures within a specified geographic region around a runway. This area is intended to capture, beyond the ground pavement areas, the operational airspace around runways to be free of land uses that create glare, smoke, or other hazards to air navigation and prohibit other potential obstacles, such as vertical structures are constructed within the extents of the RPZ.

The RSA and RPZ regions are shown below.  At this time, the FAA has deemed the RSAs and the RPZs in Elwood Logistical Airport satisfactory as designed.

Taxiway Design

Over the last decade, the FAA has published new taxiway design standards (initially in 2012 and an update in 2019) as AC 150/5340-18, Standards for Airport Sign Systems. The purpose was to identify standards for taxiway design including fillet design and overall taxiway geometry to decrease the potential for incursions, incidents, or confusing layouts. The taxiway system for KEWL was originally designed according to the 2012 taxiway system geometry standards and has since been updated to include recent design updates and has been submitted to FAA for approval.

Airport Traffic Control Tower

Elwood Logistics Airport submitted plans to operate an Airport Traffic Control Tower (ATCT) as a Federal Contract Tower controlled airfield, with operation hours from 0600 to 2200 (local time) along with the operational hours of the airport. The FAA has determined a preliminary classification for KEWL as Class D airspace. This type of airspace requires pilots to establish two-way communication prior to entering the airspace. The ATCT will also manage ground vehicles in movement areas via constant visual connection and surface vehicle transponder if needed.

An original design of the tower had located the tower at the north end of the airfield near the 10L Runway end. While this location was deemed best for the planned layout of KEWL, the placement was subsequently been moved to a site adjacent to the passenger terminal and passenger parking complex.

Airfield Lighting

Airfield lighting aids are essential during night operations and operations during adverse weather conditions. Currently the planned lighting system for KEWL has been designed to facilitate surface element identification (e.g., airfield identification beacons and obstruction lighting) along with lighting for approach paths and landing, runways, runway ends and thresholds, and taxiways.

Navigational Aids

To assist pilots with approaches and departures, airport-based navigational aids, or NAVAIDs, consist of a variety of electronic systems that vary in complexity based on the type of operations that will be occurring. Lower operational minimums for cloud ceiling and visibility require more sophisticated NAVAIDs. Since KEWL is planned for both large transport category airport (see FAA memo), precision, instrument approach NAVAIDs are required. 

Weather Sensing Systems

Operational weather for airports is provided through a system of Airport Weather Observation Stations (AWOS). The AWOS system for KEWL is planned to be installed midway between the runways north of Taxiway DD. A maintenance access road is currently being planned to extend from Taxiway DD to the site. 

Elwood Logistics Airport is applying for certification under 14 CFR Part 139 to allow for scheduled air carrier service. In addition, the KEWL includes plans for provisions of the following services: fuel services (100LL and Jet A), hangars and tie-downs, major airframe and power-plant maintenance, avionics service, customs services, and foreign trade zone. Additional considerations are currently in development for charter flights, flight instruction, aircraft rental and sales, and car rentals.

Existing plans for on-airport cargo operations facilities include two main cargo areas (listed in the Table below):

• Four terminal cargo facilities (in two tiers) with more than 800,000 sq.ft. of building space.

• Ramp area able to accommodate up to 10 Boeing 747-800 aircraft, with hydrant fueling in aircraft ramp, aircraft nose loading capability and direct airside tug access to main terminal area.

• Three (3) oversized hangars for maintenance operation accommodating any cargo aircraft type.

• Landside truck have direct access designed for maximum efficiency and segregated from public access areas for additional security.

• Additional plans for perishables processing facility under development.

Air Cargo Terminal Facilities

Ground access to the air cargo facilities are available 24-hours. Airport tower and ramp towers are also planned as 24-hour operational facilities. Four tenants have already signed agreements for occupying the cargo terminal facilities.

• The North Complex will be occupied by the third-party logistics handler, 

  • MidAmerica Freight, (in Terminal 1) 

  • All-cargo airline, GlobAm Freight (in Terminal 2)

  • Two (2) Third-Party Logistics companies located at the airport plan to coordinate demand with the adjacent intermodal facilities.

• The South Complex will have:

  • The integrated express carrier, UPZ Air Freight, is committing to full use and dedicated truck lane entry for Terminal 3.

  • FBN Air Freight that will operate in Terminal 4

The expected volume of operations for the planned year of 2025 is 500,000 tons. This baseline annual volume will be used to estimate the growth, which is expected to be 2% annually for the first 5 years, and then 3% beyond.

Passenger Terminal Facilities

While the FAA forecast for use of the airport is pessimistic on commercial operations, the Village remains optimistic that significant commercial service will exist at KEWL in a not-too-distant future. The current KEWL Master Plan includes a small General Aviation terminal facility, which has been designed to easily be expanded to include commercial traffic gates and TSA security facilities. The passenger terminal is currently in development and is seeking bids from firms to develop this. 

Maintenance Repair/Overhaul Facilities

The Maintenance Repair/Overhaul (MRO) facilities consist of three large hangars and are considered adequate for the current airport plan but will be verified following final Master Plan approval from the FAA.

Auxiliary Functions

Auxiliary functions for the airport are to be finalized upon final Master Plan approval from the FAA. This includes elements such as fuel storage capacity and handling; airport rescue and firefighting (ARFF); facilities and grounds maintenance; etc. The terminals will apply a standard model to accommodate the required US Customs and Border Patrol services for international freight.