Mammoet Completes Terminal F Module Installations at Dallas Fort Worth International Airport

30 Second Takeaway

Mammoet has successfully installed six prefabricated modules forming the first phase of Terminal F at Dallas Fort Worth International Airport. Using modular construction and self-propelled modular transporters, the modules were installed in less than two weeks, demonstrating how large-scale airport expansions can be delivered faster and with reduced disruption to ongoing operations.

Major Milestone for Terminal F at DFW

Mammoet has completed the installation of six modules that make up the first phase of the future Terminal F at Dallas Fort Worth International Airport (DFW). The operation marks a significant milestone in a multi-phase expansion programme designed to increase capacity at one of the United States’ busiest aviation hubs.

The initial phase of Terminal F has been delivered using modular construction techniques, enabling the terminal concourse to be installed in large sections in a matter of days rather than months.

Modular Construction for Airport Expansion

Faster, Safer, and More Efficient Delivery

Modular construction involves fabricating large structural elements off-site before transporting them to their final location for installation. This approach allows major construction activities to take place in parallel, reducing on-site work, improving safety, and lowering overall project risk.

For complex and space-constrained environments such as airports, modular construction offers clear advantages by minimising disruption to passengers, airside operations, and existing infrastructure.

Record-Breaking Terminal Modules

Largest Airport Terminal Modules Ever Moved

For Terminal F, Mammoet worked alongside Walsh Group, which leads the Innovation Next+ joint venture, responsible for delivering the initial 15-gate terminal concourse and a new Skylink Station.

The operation involved transporting and installing the largest airport terminal modules ever moved. The heaviest module weighed 3,320 tonnes and measured 85 metres in length, setting a new benchmark for modular airport construction.

Transport and Installation Operations

SPMTs Enable Precision Placement

The terminal modules were fabricated at a nearby site located on airport property and transported one by one to the installation area using Mammoet’s Self-Propelled Modular Transporters (SPMTs).

The SPMTs were fitted with metal support frames, allowing the modules to be lifted using the transporters’ hydraulic stroke before being driven across the tarmac and precisely positioned at their final location.

The six modules were installed in less than two weeks, highlighting the efficiency of the approach.

Project Insight

Minimising Disruption at a Busy Airport

Reid Whitley, Project Manager at Mammoet, said the project demonstrates the advantages of modular construction in complex environments.

“Modular construction techniques allow construction companies to reduce the scope of work at building sites, and for different structural elements to happen in parallel.

This can be incredibly beneficial for sites like airports, where space is limited, and lessening disruption for passengers is critical.

Mammoet prides itself on being the world leader in heavy lift and transport. This project shows another piece of what is possible with our equipment and teams.”

Ongoing Expansion Works at DFW

Supporting Multiple Terminal Projects

Prior to Terminal F, Mammoet completed a similar modular installation at DFW for a pier-style expansion at Terminal C, creating space for nine gates and delivering a net gain of four additional gates.

The next phase of the programme will see Mammoet support a similar expansion at Terminal A, continuing its role in DFW’s long-term terminal development strategy.

About Mammoet

Mammoet is a global leader in engineered heavy lifting and transport services, supporting large-scale infrastructure, aviation, energy, and industrial projects worldwide. The company is recognised for its expertise in modular construction logistics, SPMT transport, and complex installation operations.

Website: https://www.mammoet.com

Frequently Asked Questions

What project did Mammoet support at DFW Airport?

Mammoet supported the installation of six prefabricated modules for the first phase of Terminal F at Dallas Fort Worth International Airport.

How large were the terminal modules?

The heaviest module weighed 3,320 tonnes and measured 85 metres in length.

What equipment was used to move the modules?

Mammoet used self-propelled modular transporters fitted with support frames to lift, transport, and position the modules.

Why was modular construction used for Terminal F?

Modular construction reduces on-site work, improves safety, shortens schedules, and minimises disruption at busy airport sites.

What future work is planned at DFW?

Mammoet will continue supporting terminal expansion works, including a planned modular expansion at Terminal A.