How to position 3000 tons of structural framework

Transport platforms How to Position 3,307 US tons of Structural Framework

2025-08-27 By Dagmar Merger | Translated by AI 1 min Reading Time

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Mammoet has transported six gigantic modules, which will form the new Terminal F at Dallas Fort Worth International Airport, across the tarmac to their location.

The modules were manufactured at a nearby facility on the airport grounds and individually transported to the site using self-propelled modular transporters (SPMTs) from Mammoet.(Image: Mammoet) — The modules were manufactured at a nearby facility on the airport grounds and individually transported to the site using self-propelled modular transporters (SPMTs) from Mammoet.
(Image: Mammoet)

Dallas-Fort Worth Airport is being expanded. From the outset of the project, it was clear that the construction site would significantly disrupt operations. Therefore, the decision-makers devised an ambitious plan: to save time, the shell of the terminal would consist of six prefabricated sections. These sections were to be produced off-site and transported individually across the runway at night to be anchored in place on the foundations.

This modular construction method is also used for highway bridges, for example. It offers particular advantages for heavily trafficked locations, areas where space is limited, or where construction work causes significant disruptions.

Gallery

The six modules form the framework for the new Terminal F at Dallas-Fort Worth Airport.(Image: Mammoet)

On August 8, the last of six module transports was completed.(Image: Mammoet)

The individual modules were transported across the tarmac to the construction site at night.(Image: Mammoet)

Gallery with 5 images

But the components used at DFW are of spectacular dimensions: the heaviest single segment weighed 3,660 US tons and was 279 feet long. According to DFW, this is the largest module ever used for such a terminal expansion at an airport.

The construction of the terminal hall with 15 gates and a new Skylink station also involved heavy transport specialist Mammoet. Their task was to move the modules to their final location. The company used self-propelled modular transporters (SPMTs) for this purpose. With the transport and installation completed in August, further construction steps can now proceed. The hall is scheduled to be completed and operational by 2027. However, this is just one of several construction sites: in total, the airport is set to be expanded with 31 new gates, all of which will be operated by American Airlines.

Jetoptera exhibited for the first time at the Paris Air Show and announced the test results on this occasion. (Image:Jetoptera)

For Mammoet, this was not their first operation at this airport: prior to the Terminal F installation, the company assisted with the installation of a pier-like extension at Terminal C. And in the next phase of the expansion project, involving Terminal A, the heavy transport specialist will once again be involved.

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Date: 08.12.2025

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