DALLAS–FORT WORTH, TX — In a groundbreaking feat of engineering and logistics, Innovation Next+ has completed the delivery and installation of six massive prefabricated modules for the Dallas Fort Worth International Airport (DFW) Terminal F Expansion. The operation marks the largest modular terminal installation in aviation history — a milestone achieved just nine months after breaking ground.

The achievement underscores the transformative potential of modular construction in large-scale infrastructure projects. Over a carefully coordinated 12-day window, each colossal module — with the largest measuring 278 feet long, 136 feet wide, and weighing 3,320 tons — was moved more than half a mile along a DFW taxiway. The highly choreographed transport utilized Mammoet Self-Propelled Modular Transporters (SPMTs), a technology capable of shifting entire building structures with millimeter precision.

Once transported, the modules were lowered into place atop pre-built foundations at the Terminal F construction site. This precision installation was the result of extensive collaboration between construction, engineering, and airport operations teams, all working under strict safety and logistical controls to avoid disrupting ongoing airport traffic.

The project is being delivered by Innovation Next+, a joint venture of Archer Western Construction, Turner Construction Company, Phillips May Corporation, H. J. Russell & Company, and CARCON Industries, with design led by PGAL, Gensler, GFT, and structural engineering by Rogers DeSimone.

“Innovation Next+ is delivering more than a new terminal, we are demonstrating how major aviation projects can be advanced through collaboration and ingenuity. Modular and prefabricated construction are proven strategies we apply on many projects with customers who share our commitment to innovation,” said Michael Whelan, president of Archer Western’s Building Division and leading member of Innovation Next+. “This method delivers the safety, quality, schedule certainty, and efficiency our industry demands. Under the leadership of Vice Presidents Erik Logan and Brenda Premenko, the Innovation Next+ design-build team had the vision and confidence to take on a bold approach, making history at DFW with the largest and heaviest terminal modules ever moved.”

"This bold, modular, and innovative approach is redefining what’s possible at DFW," said Abrar Sheriff, President of Turner Construction Company. "In just nine months, Innovation Next+ delivered and set in place six massive, prefabricated modules – the largest ever for an airport terminal. This achievement speeds completion, enhances worker safety, and sets a new industry benchmark for precision and efficiency. Our work will elevate the passenger experience and drive lasting economic growth for the region."

When complete, the Terminal F Expansion will feature a double-loaded concourse with 15 new gates, expanded passenger amenities, and upgraded operational systems. Beyond increasing passenger capacity, the expansion will serve as a showcase of how modular building technology can transform complex aviation projects — cutting timelines, improving worker safety, and minimizing disruption to active airport operations.

Industry experts note that the Terminal F project could serve as a blueprint for future major airport builds, offering a compelling case for adopting large-scale modular methods in an era where construction schedules are tightening and passenger demand is rising.

With its combination of size, speed, and precision, the DFW Terminal F modular milestone sets a new global standard — one that blends construction innovation with operational excellence, ensuring that one of the world’s busiest airports is ready for the future of air travel.

Originally reported by Turner Construction Company.