Six huge, prefabricated structural modules have been placed onto foundations to form the framework for the first phase of Dallas Fort Worth’s (DFW) new Terminal F.
They were moved overnight along one of the airport’s taxiways using self-propelled modular transporters, or SPMTs.
The biggest module was 278ft long, 136ft wide and weighed 3,320 tonnes, the equivalent to 12 Boeing 787-9 Dreamliner aircraft.
DFW said the operation broke the record for size of modules used at any terminal expansion.
They were four times bigger than those used for the airport’s Terminal C expansion.
Construction began on the $1.6bn first phase of Terminal F in November 2024. Due to be completed in 2027, it will have 15 gates.
The full, $4bn Terminal F expansion will deliver 31 gates, all to be operated by American Airlines, with increased capacity for international flights and widebody aircraft.
It will include a new light rail station and a walking connection to Terminal D. The airline will return some gates to competitors elsewhere in the airport.
The project is being designed and built by “Innovation Next+”, an American consortium made up of Archer Western Construction, Turner Construction, Phillips May Corporation, HJ Russell & Company and Carcon Industries. The consultants include Gensler, PGAL and Muller2.
Mohamed Charkas, DFW’s executive vice president of infrastructure and development, said: “DFW is at the forefront of innovation in terminal construction, continually redefining what’s possible.
“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.”
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