Dallas–Fort Worth, Texas – Innovation Next+, the design-build joint venture, has achieved a historic milestone with the successful modular delivery and installation of six prefabricated modules for the first phase of Dallas Fort Worth International Airport’s (DFW) Terminal F Expansion. This marks the largest modular construction operation ever undertaken for an airport terminal.
The first move took place just nine months after groundbreaking, showcasing the speed and efficiency of modular construction. Over 12 days, the modules—the largest measuring 278 feet long by 136 feet wide and weighing 3,320 tons—were transported more than a half mile down a DFW taxiway using Mammoet Self-Propelled Modular Transporters. The operation highlighted engineering excellence, logistical expertise, and precise execution.
The project is being led by Innovation Next+, a joint venture of Archer Western Construction, 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,” said Michael Whelan, President of Archer Western’s Building Division. “This bold modular approach ensures safety, quality, schedule certainty, and efficiency, setting history at DFW with the largest and heaviest terminal modules ever moved.”
Abrar Sheriff, President of Turner Construction Company, added: “This innovative approach is redefining what’s possible at DFW. In just nine months, we delivered and set in place six massive prefabricated modules – the largest ever for an airport terminal. This effort accelerates project completion, enhances worker safety, and establishes a new industry benchmark for efficiency and precision.”
Once completed, Terminal F will feature a double-loaded concourse with 15 gates, expanded passenger amenities, and improved operational capacity. The expansion is expected to significantly increase passenger throughput, elevate customer experience, and set a new standard for modular construction in global aviation projects.
