Innovation Next+ Achieves Landmark Modular Delivery for DFW Terminal F Expansion

DALLAS–FORT WORTH, TEXAS – Six massive, prefabricated modules for the first phase of Dallas Fort Worth International Airport’s Terminal F Expansion have been successfully transported and set, marking the largest-scale modular operation ever undertaken for an airport terminal. The first move took place just nine months after the project’s groundbreaking, demonstrating the speed and efficiency made possible by a modular construction approach. Over a span of 12 days, each module, with the largest measuring 278 feet long by 136 feet wide and weighing 3,320 tons, was carefully moved more than a half mile down one of DFW’s taxiways using Mammoet Self-Propelled Modular Transporters, a highly choreographed process that demonstrated engineering excellence and logistical expertise. The structures were then placed onto the foundations constructed at the Terminal F site, where the Innovation Next+ design-build team will continue to the next stage of construction.

The historic effort was conceptualized and managed by Innovation Next+, a joint venture led by Archer Western Construction in partnership with Turner Construction Company, Phillips May Corporation, H. J. Russell & Company, and CARCON Industries, with design partners PGAL, Gensler, GFT, and structural engineer Rogers DeSimone.

“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,” said Michael Whelan, president of Archer Western’s Building Division and leading member of Innovation Next+. “This method delivers the safety, quality, schedule certainty, and efficiency our industry demands. Under the leadership of Vice Presidents Erik Logan and Brenda Premenko, the Innovation Next+ design-build team had the vision and confidence to take on a bold approach, making history at DFW with the largest and heaviest terminal modules ever moved.”

"This bold, modular, and innovative approach is redefining what’s possible at DFW," said Abrar Sheriff, President of Turner Construction Company. "In just nine months, Innovation Next+ delivered and set in place six massive, prefabricated modules – the largest ever for an airport terminal. This achievement speeds completion, enhances worker safety, and sets a new industry benchmark for precision and efficiency. Our work will elevate the passenger experience and drive lasting economic growth for the region."

When complete, the Terminal F Expansion will feature a double-loaded concourse with 15 gates and modernized customer amenities, while significantly increasing passenger capacity, improving operational efficiency, and setting a new standard for modular building technology in large-scale aviation projects.