Dallas Fort Worth International Airport (DFW) continues to have its experience in modular construction at new heights, recently placing six prefabricated modules of “megastructure” on the site of its Terminal C terminal reconstruction and expansion program of $ 3 million.
Each module, the largest of which measured 204 feet X 68 feet and weighed approximately 1,200 tonnes, transported about one mile of a manufacturing garden by means of modular transporters self -propelled by Mammoet (SPMTS). The movements were made for six closures of the track overnight for a period of two weeks.
Part of the initial phase of 115,000 squares of DFW collaboration with American Airlines to update terminal C, the modules form a double loaded dock that will provide nine doors when the construction is complete by 2026. To create an 80,000 square meters enclosure for the four high “C” doors of the terminal.
In addition to being almost twice as large as the basic units and shells, which adapted after being in place, Charkas says that the moll modules had 75% of their MEP protection systems and already installed.
“The pipes, the cable trays and other pieces to connect the modules were on the only components not included,” he says, adding that a module also had a pre -installed terrazzo soil as proof.
“He perfectly managed the move,” he says.
The need to place precisely the moll modules in a two -dimensional configuration added to the complexity of the joint company of the design design project: Astin Commercial, Azteca Enterprises and Alpha & Omega, also known as AAA. The Kelley Locke project executive, Vice President of Austin Commercial Aviation Division Operations, says that a year of planning, a design information design (BIM) of field work assured that the modules would align as they were intended with their foundations and one another.
Locke states that while DFW’s previous experience with modular transport provided a good starting point, “these units were larger and partially in shape, which meant calculating the turn radius to keep everything on the track. We also had to engine them to function not only as a finished building, but also to survive the move.”
Planning paid for fruits, according to Locke. The movements were performed perfectly, including the module coating in their 36-foot concrete columns in diameter 36 feet.
“The largest module was established in 20 columns, although the transport had between a fourth and a half inch of specifications when it came in,” he says. “Some adjustments and everything was perfect.”
More prefabricated modules will be in motion in DFW in the coming months, as the airport pursues its $ 9 million capital improvement program. In mid -August, the joint company AAA will transport seven prefabricated modules to the place of the 140,000 square meters in expansion, another double -charged wharf style configuration that increases the capacity with 10 new doors.
Locke says that although this movement will be twice the distance from the Ter Terminal C project, the experience, along with the cooperation to the entire team, provides a solid base to ensure success.
“It may fit these modules even more, such as putting more soil and maybe a little dry land,” he adds.
The following month, a more aggressive prefabrication effort will be seen as part of the first phase of terminal F, a project of $ 1.6 million, 400,000 square meters set out in the first completely DFW terminal in 20 years.
The 15 -door double -loaded concourse will consist of six modules up to 270 x 120 feet, requiring what Charkas says will be an even greater level of precision robotic transport, construction and synchronization. The Ter Terminal Fill design team is led by a joint company of the Archher Western construction company, Turner Construction, Phillips May Corporation, HJ Russell & Company and Carcon Industries.
Charkas states that, while DFW has the advantage of the Earth to locate manufacturing gardens near construction places, modular construction can benefit any airport that is issued by creating installations with adaptable and flexible planes.
“The aviation business must constantly evolve to meet new expectations,” he adds. “Modularity will take us there.”
