Case Study Abstract: Rehabilitation of Runway 17R/35L at Dallas Fort Worth International Airport

Abstract: Dallas Fort Worth International Airport (DFW) recently completed a major rehabilitation of Runway 17R/35L, a critical 13,400-foot-long and 200-foot-wide runway responsible for 50% of all departure traffic at the world’s third busiest airport. This intensive project involved resurfacing and infrastructure upgrades, including the placement of 310,000 tons of asphalt and 200,000 cubic yards (CY) of Portland Cement Concrete (PCC) in less than one year. The project also modernized lighting systems, upgrading 2,725 fixtures to LED, replacing 845,000 linear feet (LF) of electrical cables, and updating key airfield infrastructure such as guidance signs, electrical manholes, and junction cans.
A significant innovation in this project was DFW’s first use of concrete maturity sensors to monitor the curing process in real time. This technology expedited understanding of concrete strength development, allowing the project team to make data-driven decisions about load-bearing readiness. As a result, critical sections of the runway were reopened faster without compromising quality, further optimizing the project schedule.
Aligned with DFW’s commitment to sustainability, the project recycled approximately 300,000 CY of existing concrete, repurposing it as a base for the shoulder of the new runway and associated taxiways. The design emphasized economic efficiency, sustainability, long-term performance, and minimal impact on ongoing operations.
Rehabilitating an inboard runway close to terminal areas posed unique logistical challenges, as it required keeping DFW’s six other runways operational. To address this, the project team implemented a phased construction schedule, strategically opening major cross taxiways in stages and allowing phased runway use at a shortened length. Advanced scheduling software was employed to optimize resource and time allocation, enhancing coordination across construction phases.
Thanks to these innovations, the shortened section of the runway was completed and operational a week ahead of schedule, ensuring no disruption during the peak summer travel season. The full runway was reopened in October 2024, five days ahead of schedule.
This case study highlights how adaptive project management, innovative design, and effective use of technology—such as maturity sensors—can address complex construction challenges. The project’s success underscores the value of careful planning and technological advancement in enhancing efficiency and cost-effectiveness, setting a new benchmark for future airfield rehabilitation projects.