This unique project was the first asphalt runway to be constructed in the 40-year history of DFW International Airport. More than $106 M worth of asphalt, concrete, earthwork, and electrical systems had to be constructed on an accelerated schedule of less than one year.
As the prime contractor, Austin Bridge & Road’s scope of work included 50’ keel replacement (17” concrete), 35’ shoulder reconstruction, mass site excavation, 5” to 23” concrete taxiway transition replacement, concrete crushing, lime subgrade, storm drainage, and a 6” asphalt overlay. All materials and workmanship were produced and installed in accordance with FAA specifications. Additional scope included airfield lighting and replacement, saw-cut grooving, and striping.
Austin produced and paved a remarkable 225,000 tons of P-401 HMAC in five months through a record rainfall season and frigid seasonal temperatures. Austin used the Trimble PCS900 Paving Control System for the HMAC runway paving on this project for the highest level of accuracy and quality results. The system utilizes a Universal Robotic Total Station and on-board hardware and software to control the paver to the desired final surface requirements. The biggest challenge on this project was 54 inches of rain in September of 2018 - a prime month for laying asphalt. To push the project forward, Austin used as many as 300 team members working 24/7, totaling approximately 172,000 man hours.
Given the large contingent of workers, the airport instituted a certified movement area escort program that allowed contractor personnel trained in airport operations to guide materials and workers throughout the secure airfield areas.
This project was awarded DFW's 2019 Project of the year!