McCarthy Building Cos. topped out structural steel on the new Terminal C at John Wayne/Orange County Airport when construction workers from W&W Steel Co. lifted and secured the final steel beam to the top of the structure.

Over the last four months, construction workers used a 350-ton crawler crane to install 2,400 pieces of structural steel for the new terminal.

Serving as the general contractor for the project, McCarthy is building a new 280,000-sq-ft, three-level terminal with six bridged aircraft gates at the airport. The new terminal is being built just south of the existing terminal complex. Once completed, John Wayne Airport will house a total of 20 commercial passenger gates, two of which will be capable of connecting to Federal Inspection Services (customs) facilities allowing JWA to accommodate international flights.

Additionally, new commuter passenger terminals with space for up to three commuter/regional jets at the north end of Terminal A and three commuter/regional jets at the south end of Terminal C are being built.

McCarthy is also performing upgrades and renovations to the existing Terminals A and B. The $102.3 million construction project is part of the Airport Improvement Program, one of Orange County�s largest-ever public works programs.

�We are conducting a very detailed plan for the project due to the logistics of building in an operational airport facility; a constricted site bounded by airport operations and roadways; and tight security constraints at the airport,� says Khatchig Tchapadarian, McCarthy�s project manager. �In order to minimize any impact to airport operations, the project is being phased, some construction work is being conducted at night and barricades have been installed.�

With architectural and engineering provided by Gensler of Newport Beach, Terminal C is being built with a structural steel frame and cast-in-place concrete. To maintain a seamless connection between all three terminals, the new building�s exterior skin will incorporate masonry, plaster, and stone along with glass and metal panels similar to the existing structures. The interior features vaulted ceilings resembling a fuselage, several windows and skylights.

Terminal C will house a centrally located concessions area on the second level, surrounding a three-story atrium; baggage claim with three baggage carousels as well as a separate security screening area. Additionally, custom-designed power receptacles located between the backs of the passenger seating rows will allow travelers to power up their cell phones, laptop and other electronic devices while waiting for their flight.

Environmentally responsible construction techniques are being used throughout the project, including curbing storm water runoff from the construction sites to prevent discharge of pollutants to the storm drains; recycling 90% of construction-related materials and waste; and dust mitigation activities to minimize air quality effects during construction.

Some of the structure�s sustainable aspects feature utilization of natural lighting and other methods to maximize energy efficiency as well as a Water Quality Management Plan, which incorporates environmental controls into the building designs and specifies the means and methods of pollution control after completion of the buildings.

Parsons of Pasadena is the program manager; Arcadis/Pinnacle One of Irvine is the construction management firm; Jacobs of Santa Ana is the civil & MEP engineer; and IDS Group, Inc. of Irvine is the structural engineer. The main specialty contractors are Capparelli/KHS&S of Orange (framing/drywall), Helix of San Diego (electrical), A.O. Reed of San Diego (HVAC) and Pan Pacific Plumbing of Irvine (plumbing).

Construction began in August 2009 and is scheduled to open to the public in late 2011.