Dallas Fort Worth International Airport (DFW) continues his experience in modular construction to new heights and has recently placed six prefabricated “megastructure” modules at the location of its current 3-billion dollar-C reconstruction and expansion program.
Each module from which the largest 204 FT X 68 feet and approximately 1,200 tons weighed about a mile was transported by a manufacturing courtyard using mammoet-known modular transporters (SPMTS). The movements were carried out overnight during six individual runway closings overnight.
Part of the 115,000 SQ-FT beginnings of the DFW partnership with American Airlines to improve the layout of Terminal C form a double-loaded pier that delivers nine new gates that are completed in 2026. Mohamed Charkas. An 80,000 square meter hall for the four “high C” goals of the terminal.
In addition to the core and shell units that were equipped after the introduction, the pierules were not just twice as large as these core and shell units, which had already installed 75% of their MEP and fire protection system.
“The pipes, cable shells and other parts for connecting the modules were approximately the only components that are not included,” he explains, adding that a module had also pre-installed terrazzo floor load as a test.
“The movement handled perfectly,” he says.
The need to position the pierules exactly in a two-dimensional configuration, added to the complexity for the joint venture of the design building project-excess Commercial, Azteca Enterprises and Alpha & Omega, also known as AAA. The project manager Kelley Locke, Vice President of Operations at the National Aviation Division of Austin Commercial, says that a year of planning and field work is planned for one year to ensure that the modules would be aligned with its foundations and another.
Locke notes that the earlier experience of DFW with the modular transport was a good starting point, “these units were larger and partially equipped, which meant to calculate the rotary radius to keep everything on the runway. We also had to develop in order not only to act as a finished building, but also to survive the step indispensable.”
The planning paid off, says Locke. The movements were carried out flawlessly, including the lining of the modules in their 10-footbal concrete pillars with a 36-in-diameter.
“The largest module was set on 20 pillars, but the transport had it within a quarter up to half a customs specification when it rolled up,” he says. “A few adjustments and everything was perfect.”
Other prefabricated modules will be in motion at DFW in the coming months, since the airport is pursuing its diverse capital improvement program of $ 9 billion. In mid-August, the AAA-Joint Venture transports seven prefabricated modules to the location of the 140,000 square meter terminal A expansion, a further configuration in a double-loaded pier style, which increases the capacity with 10 new goals.
According to Locke that this step is twice as high that the Terminal C project is twice as high, experience in connection with team-wide cooperation offers a solid basis for success.
“We can do these modules even more, such as more terrazzo and maybe some drywall construction,” he adds.
The following month, as part of the first phase of Terminal F, a 400,000 square meter project of $ 1.6 billion, which marks the first completely new terminal from DFW in 20 years, will be more aggressive prefabrication effort.
The 15-gate double-loaded hall is formed by six modules of up to 270 x 120 feet, which will make Charkas an even greater level of precision design, construction and synchronization of robot transports. The design building team from Terminal F is directed by a joint venture by Archer Western Construction, Turner Construction Company, Phillips May Corporation, HJ Russell & Company and Carcon Industries.
Charkas notes that DFW has the advantage of the country to localize the manufacturing courtyards in the immediate vicinity of building sites, but modularly construction will benefit every airport in order to accelerate the creation of facilities with customizable and flexible floor plans.
“The aviation business has to constantly develop in order to meet new expectations,” he adds. “Modularity will bring us there.”