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

PGAL, in collaboration with the Innovation Next+ design-build team, is proud to announce the successful transport and placement of six massive prefabricated modules for the first phase of Dallas Fort Worth International Airport’s Terminal F Expansion. This milestone marks the largest-scale modular operation ever undertaken for an airport terminal and underscores the speed, precision, and innovation that define the project.

The first module move occurred just nine months after groundbreaking, a testament to the efficiency achievable through modular construction. Over the course of 12 days, each module—one measuring an impressive 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. Utilizing Mammoet Self-Propelled Modular Transporters, this highly choreographed process showcased world-class engineering expertise and logistical coordination. Once transported, the modules were set on foundations at the Terminal F site, where construction continues toward the next phase.

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. PGAL, along with Gensler, GFT, and structural engineer Rogers DeSimone, is proud to serve as a design partner on this transformative project.

“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. The project will significantly increase passenger capacity, improve operational efficiency, and set a new benchmark for modular building technology in large-scale aviation projects.