PGAL served as the lead design firm for the nation’s first airport concourse built using large-scale prefabricated modular construction.
The nearly 80,000-square-foot, two-level DFW High C Gates facility was developed using an innovative prefabricated modular shell-and-core system that allowed significant portions of the terminal to be constructed off-site while airport operations continued. Completed modules were transported across active airfields overnight and installed in carefully coordinated phases, reducing the amount of construction activity required within the active terminal environment and minimizing impacts to passengers, aircraft, and airport operations.
The modular approach required close coordination across architecture, engineering, fabrication, transportation, and installation. PGAL also played a central role in integrating the modular design with adjacent areas of DFW Terminal C, coordinating off-site delivery with engineers and specialty consultants, and managing the complex phasing required to bring the prefabricated components onto an active airfield. The completed concourse accommodates five narrow-body aircraft or regional jets and provides an updated domestic travel experience.
As the first U.S. airport concourse to use large-scale modular construction, the DFW High C Gates project demonstrated the potential of prefabrication to accelerate terminal delivery while maintaining quality and meeting the complex requirements of an active airport. The project established an approach that continues to inform the evolution of modular aviation design and construction.
