b'RUNWAYSDFW 71table with pretty much an open mind andFuture maintenance was also a key wanted to have a solution, he remarks. consideration, which is why the airport Rafat Sadat, senioropted for a hybrid of high-density asphalt project manager withover concrete in lieu of a concrete surface AECOM, notes thatfor the project. You can mill and overlay in extensive coordinationa shorter period of time, hence you dont was needed withhave to take the runway out for many, the airlines, FAA andmany months, Charkas explains. airfield operationsWith a high-density mix asphalt overlay to come up with theRAFAT SADAT rather than full concrete, the repair cycle most efficient designbecomes much easier and less impactful and phasing to minimize operationalto operations, Sadat agrees. This is a impacts. tested approach for the airport, as the first At 13,400 feet long and 200 feet wide,asphalt runway at DFW was completed Runway 17R-35L is not only one of DFWsin 2018, and that asphalt surface is widest runways, it is also the primaryoutlasting its expected five- to seven-year departure option on the east side of thelifespan. Based on the course the team is airfield. As such, it was important for thetaking and the evaluation, we believe we project team to maintain accessibilitystill have two to three years until the first to end-around taxiways on both theasphalt overlay is needed, Charkas notes. north and south ends of itas well asHence, we believe that staying on the connectors in the middlethroughoutasphalt course really benefits DFW both in construction.the project timeline and for the lifecycle of the product.Design, planning and detailed sequencing of the complex projectIn addition to resurfacing 17R-35L, took about a year. Initially, the designDFW installed a new lighting vault to team planned to divide work amongpower the east airfield. At 50 years old, three phases to support ongoing airlinethe original lighting vault was also due for operations. The northern and southernrehabilitation, so the airport scheduled DFW received a $45 million FAA Airportthresholds would be replaced separately,it concurrently. Substantial completion Infrastructure Grant under the Bipartisankeeping the middle of the runway open.of the vault was 15 days prior to 17R, Infrastructure Law to assist in funding theand, hence, the electric power to supply $257 million investment. The rehabilitationThen, the team came up with this reallythe lights on the new runway came project was completed by Austin Bridgecreative idea, Charkas shares. Instead offrom the new, updated lighting vault we & Road, with design by AtkinsRalisthree phases, the project was reduced toconstructed, says Charkas. and program management by Airfieldjust two. Preliminary work was completed Management Partners JV, a joint ventureon one of the thresholds, and then DFW fullyChallenges and Triumphsbetween AECOM and H.J. Russell. closed Runway 17R-35L in August 2023The project team used concrete maturity after the busy summer travel season ended.meters to help move the runway work Collective InnovationIn just nine months, crews completed aalong at an aggressive pace. Crew In 2018, DFWs engineering evaluationfull asphalt overlay on about two-thirds ofmembers placed meters into the concrete, process and condition assessmentsthe runways total length. They finished oneabout 4 inches from the top, to help determined that the aging runway wouldweek ahead of schedule and just in timedetermine when pavement was ready need a full rehabilitation within five years.to allow 17R-35L to reopen in a shortenedfor subsequent work. The tools provided Planning for the comprehensive projectconfiguration of 9,275 feet for the nextreal-time information about concrete began in early 2022, including developmentsummer uptick. This 9,275-foot lengthtemperature and strain on the sensors, of the phasing approach that proved to beallowed 90% of DFWs fleet mix to usewhich are indicators of concrete strength. so pivotal.the key departure runway during the busyThose gave us a secondary data point to summer travel season while work continuedmake educated decisions on when to open Because Runway 17R-35L is suchon the remaining southern one-third of thesurfaces, Sadat explains.a crucial piece of the DFW machine,pavement. The entire newly resurfaced Charkas emphasizes that it was imperativeIn addition to an ambitious timeline, runway reopened on Oct. 11, 2024.team members faced other challenges, for all stakeholders to be represented during planning to ensure safe, secure andEverybody collaborated because of theincluding supply chain issues and volatile timely delivery. Everybody came to theimportance of the return of the asset tomaterial prices. An industry-wide fly ash service, explains Charkas.shortage inspired the contractor and AirportImprovement.comJanuary | February 2025'