A major construction milestone has been reached at Dallas Fort Worth International Airport (DFW), where contractors successfully placed six massive prefabricated modules for the airport’s $855 million Terminal F and Skylink expansion project, part of a broader $4 billion redevelopment plan.

According to Turner Construction, which is part of the project’s design-build joint venture, the installation marked “the largest-scale modular operation ever undertaken for an airport terminal.”

Over the course of 12 days, crews carefully moved and anchored the prefabricated components, the largest of which measured 278 feet long, 136 feet wide, and weighed 3,320 tons. The modules were transported half a mile down one of DFW’s taxiways using Mammoet Self-Propelled Modular Transporters, advanced heavy-lift machines that function as massive mobile platforms.

The placement occurred just nine months after groundbreaking, a rapid timeline for a project of this magnitude.

The Innovation Next+ joint venture is delivering the design-build project and includes:

• Archer Western Construction (Chicago)
• Turner Construction (New York)
• H.J. Russell & Co. (Atlanta)
• Phillips May Corp. and Carcon Industries (Dallas)
  On the design side, PGAL, Gensler, and Muller2 are leading architecture and planning efforts.

When complete, Terminal F will feature a double-loaded concourse with 15 gates, modern passenger amenities, and increased operational capacity. The expansion is also tied to the new Skylink connection, which will enhance connectivity between terminals and streamline passenger movement across the airport.

Michael Whelan, president of Archer Western’s building division and a leading member of the JV, emphasized the innovative construction methods used:
“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.”

The broader $4 billion DFW expansion is designed to position the airport for long-term growth, with passenger traffic expected to rise significantly in the coming decade. The Terminal F project also reflects the aviation industry’s increasing reliance on off-site modular construction to reduce costs, minimize on-site disruption, and accelerate delivery schedules.

DFW, already one of the world’s busiest airports, is investing heavily in infrastructure upgrades to stay ahead of demand. Once complete, Terminal F will not only add much-needed gate capacity but also introduce cutting-edge technology and enhanced passenger experiences, aligning with the airport’s strategic plan to remain a global leader in air travel.

Originally reported by Matthew Thibault in Construction Dive.