DFW Terminal C - High C Gates, Unitized Modular Concourse

Dallas-Fort Worth

Award of Merit


Owner: Dallas-Fort Worth International Airport

Lead Design Firm: PGAL

Design-Builder: The Walsh Group

Structural: Henderson Rogers Structural Engineers LLC


Heavy Haul Contractor: Mammoet USA South

Ready Mix Concrete Supplier: Redi-Mix Concrete

Delivered under a progressive design-build contract, crews replaced the existing DFW Terminal C high gates with a new modular core and shell envelope. The modules were fabricated off site, providing a controlled environment to help ensure quality and safety.

During a three-week period, the modules—complete with metal panels and glazing—were transported 1.5 miles across the airfield from the prefabrication yard to the site. Crews made these moves every other night using three self-propelled modular transporters. Each transport took up to 45 minutes to move from the fabrication yard across the runways, under the Skylink automated people mover and between columns. Crews then jacked each module up 8 ft and set it in place adjacent to the Skylink.

While modules were fabricated, construction at the site progressed simultaneously. Crews carried out demolition, grading, foundations and underground utilities. The method resulted in turnover of the concourse that was 22% faster than traditional stick-build methods.

As a first-of-its-kind use of modular construction, the team did not have best management practices to reference. Design-assist packages were awarded for glazing, metal panels and structural steel to work out design tolerances. The strategy helped enable the team to fabricate fully cladded modules. Work was completed in May, on budget and ahead of schedule.