Mammoet Completes Installation of Record-Breaking Terminal F Modules at Dallas Fort Worth Airport

Mammoet has successfully supported the installation of six modules that make up the first phase of the future sixth terminal at Dallas Fort Worth International Airport (DFW), marking a significant milestone in a multi-phase project to expand capacity at the major US hub. This initial phase of Terminal F has been built using modular construction techniques—a method in which large structures are prefabricated off-site, in sections, before being transported to their final location and connected. This approach enables large construction and infrastructure projects to be completed faster, safer, and more cost-effectively. For busy sites like airports, where space is limited and civil work can cause significant disruptions, modular construction offers major advantages.

For Terminal F, Mammoet worked with Walsh Group, which led the Innovation Next+ joint venture to build the initial 15-gate terminal concourse and new Skylink Station. The operation involved moving the largest airport terminal modules ever transported, with the heaviest unit weighing 3,320 tons and measuring 85 meters in length.

The modules were fabricated at a nearby site on airport property and transported one by one on Mammoet Self-Propelled Modular Transporters (SPMTs). The SPMTs were fitted with metal supports, which allowed the modules to be lifted using the stroke of the transporters before being carried across the tarmac and installed at their new location.

Reid Whitley, Project Manager at Mammoet, said: “Modular construction techniques allow construction companies to reduce the scope of work at building sites and carry out different structural elements in parallel. This is particularly beneficial for airports, where space is limited and minimizing disruption for passengers is critical. Mammoet prides itself on being the world leader in heavy lift and transport. This project is another example of what is possible with our equipment and teams.”

Prior to the Terminal F installation, Mammoet performed a similar operation at the airport for a pier-style expansion at Terminal C, adding a net gain of four gates. The next stage of the project will see Mammoet support a similar expansion of Terminal A.