Dallas Fort Worth International Airport (DFW) has reached a major construction milestone with the successful placement of six massive prefabricated modules, forming the structural framework for the first phase of the airport’s new Terminal F. The milestone marks a significant step forward in the $4 billion terminal expansion project.
On August 8, the airport completed the final module move after a two-week series of overnight operations. Using self-propelled modular transporters, crews carefully transported the enormous structures along an airside taxiway before positioning them on the foundations prepared at the Terminal F site. Some of the modules measured nearly the size of a football field, with the largest stretching 278 feet long, 136 feet wide, and weighing 3,320 tons—roughly the equivalent of 12 Boeing 787-9 Dreamliner aircraft.
This is DFW’s third project to deploy modular construction for terminal facilities. The Terminal F modules are approximately four times larger than those moved earlier this year for the Terminal C expansion, highlighting the airport’s use of innovative construction methods to accelerate project timelines while minimizing disruption to passengers and operations.
The first phase of Terminal F is scheduled to open in 2027 with 15 gates. The completed terminal is planned to ultimately include 31 gates, serve as a hub exclusively for American Airlines, expand capacity for international flights and widebody aircraft, and feature ticketing, check-in, security screening, baggage handling, and parking facilities. A centralized Skylink Station included in the first phase will connect Terminal F to Terminal D via a walking corridor.
“The milestone reflects the dedication and vision of the many teams building the future of our airport,” said DFW CEO Chris McLaughlin. “By embracing modular construction, we are finding smarter ways to deliver results faster, with less impact on travelers.”
DFW Executive Vice President of Infrastructure and Development Mohamed Charkas added, “The time saved using modular construction is crucial for supporting our airline partners and fostering growth in North Texas. This approach ensures we continue to serve as an economic engine while delivering state-of-the-art facilities.”
The Terminal F first phase design-build team is Innovation Next+, a joint venture comprising Archer Western Construction, Turner Construction Company, Phillips May Corporation, H. J. Russell & Company, and CARCON Industries. PGAL, Gensler, and Muller2 provide architectural and design services for the project.
In May, DFW and American Airlines announced an expansion and acceleration of the Terminal F phasing plan. The airport continues designing subsequent phases of the terminal while constructing modules offsite, ensuring that future expansions can proceed efficiently. Once complete, Terminal F will enhance passenger experience, increase operational capacity, and strengthen DFW’s position as one of the nation’s leading international airports.
