Dallas Fort Worth Airport completes record-breaking modular move as new terminal f construction reaches major milestone

Credit: Dallas Fort Worth International Airport (DFW)

The future of Dallas Fort Worth International Airport (DFW) has taken another step forward with the completion of a major construction milestone for the new Terminal F. On 8 August, the airport finished moving the last of six prefabricated module structures that form the framework for the terminal’s first phase.

The modules, some almost the size of a football pitch, were transported overnight during a two-week period using self-propelled modular transporters along one of DFW’s airside taxiways. They were then placed onto prepared foundations at the Terminal F site, allowing construction to move to the next stage.

This is the third time DFW has used modular construction to expand or reconstruct terminal facilities. The latest modules are the largest ever used for a terminal expansion at any airport, around four times bigger than those used earlier this year for Terminal C’s expansion. The largest module measured 278 feet in length, 136 feet in width and weighed 3,320 tonnes, about the same as 12 Boeing 787-9 Dreamliner aircraft.

“This milestone reflects the dedication and vision of the many teams who are building the future of our airport,” said DFW’s CEO Chris McLaughlin. “Together with our partners, we are delivering infrastructure through innovation and collaboration that will serve the growing needs of North Texas while setting the stage for the next era of DFW’s development. By embracing modular construction, we are finding smarter ways to deliver results faster, with less impact on travellers.”

“DFW is at the forefront of innovation in terminal construction, continually redefining what’s possible,” added Mohamed Charkas, Executive Vice President of Infrastructure and Development. “The time we save using modular construction techniques is crucial for fostering the growth of our community and supporting our airline partners. We are steadfast in our commitment to being an economic engine for North Texas.”

In May, DFW and American Airlines announced they would expand the scope and accelerate the phasing of Terminal F. The first phase, now underway, is due to open with 15 gates in 2027.

The £3.1 billion (US$4 billion) project will ultimately deliver 31 gates, all to be operated by American Airlines, with increased capacity for international flights and widebody aircraft. Facilities will include parking, ticketing, check-in, security screening and baggage handling, as well as a new central Skylink Station and a walking connection to Terminal D. American will also return some gates elsewhere in the airport to support the growth of other airlines.

The design-build team for phase one is Innovation Next+, a joint venture including Archer Western Construction, Turner Construction Company, Phillips May Corporation, H. J. Russell & Company and CARCON Industries, with PGAL, Gensler and Muller2 as designers.

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