Big moves in airport construction

Modular construction is reshaping how airport terminals are being built across the globe, writes Corgan’s Jonathan Massey.

Modular construction is emerging as a powerful tool to modernise ageing aviation infrastructure while maintaining operations, offering clear advantages to airlines and airport stakeholders at some of the busiest airports in the world.

It has various associated terminologies describing a variety of related methods, such as modern methods of construction (MMC), design for manufacture and assembly (DfMA), or a ‘kit of parts’.

While all of these methods have their benefits, a handful of high-profile aviation projects in the United States have now benefitted from using large-format volumetric modules.

In this method, the major built components — ‘modules’ — are constructed away from the active aircraft stands and moved into place when they are in a near completion, reducing gate down time significantly relative to traditional construction methods.

Modules are transported across the airfield at night to minimise disruption to airport operations. Once positioned, they are seamlessly joined to enclose the structure and integrate building systems, enabling interior work to proceed.

Deploying this approach offers a way to make necessary upgrades to facilities with minimal disruption and with drastically reduced loss of revenue.

MAKE IMPROVEMENTS, NOT (OPERATIONAL) IMPACT

Regardless of the reason for a gate closure — be it weather, security, or construction — the cost of closing a gate is high.

Corgan’s estimates show that airlines and airports lose between $300,000 and $400,000 in revenue per day per gate when out of operation.

Off-site modular construction, along with careful phasing, can significantly reduce the financial and operational impact of upgrades on both the airport and airline.

This method was used to rapidly replace American Airlines’ High C Gates at Dallas Fort Worth International Airport (DFW) while flights were on a reduced schedule during the COVID-19 pandemic.

After the original five gates were demolished, the DFW-led design-build team installed the modular envelope while the Corgan team, led by American Airlines, designed the interior fit-out of the space.

Co-ordination between the two design and construction teams facilitated early access for interior work prior to construction being completed on the shell and core, further increasing efficiency in both cost and schedule.

This overlap in construction work areas, combined with the off-site construction of the modules, saved the airport four months compared to a traditional construction approach. As a result, all gates were fully operational when flight schedules returned to normal.

By using modular construction for the current Concourse D widening project at Hartsfield-Jackson Atlanta International Airport (ATL), Corgan has enabled airlines to save an estimated $500 million in otherwise-lost revenue.

The complex renovation and expansion is being conducted in a multi-phased approach, enabling the concourse to remain operational, significantly reducing both gate closure time and the overall project timeline.

In this case, gate closure time is reduced by combining modular and traditional methods: the modular expansions allow for new gate expansion, which in turn facilitates traditional renovation construction on the existing concourse.

At ATL, the modular construction schedule saves the airport more than 40 weeks of gate closures and reduces gate downtime by 20% compared to a traditional approach.

To increase the speed of the overall construction timeline, the team closed eight gates at once, rather than doing a few at a time. This saved nearly three years of phased construction, or a third of the original timeline.

In phase two, the team proposes to close 10 gates simultaneously, saving an additional five months.

Corgan is also leading the design of a complete reconstruction of Terminal 5 at Los Angeles International Airport (LAX) in time for the global spotlight of the 2028 Los Angeles Olympics.

To meet this ambitious schedule, the landside headhouse will be built using traditional, on-site construction methods, while the airside concourse will use prefabricated, off-site modular construction.

This approach allows demolition, early foundation, and utilities work to proceed simultaneously with construction of the new concourse, realising significant time savings compared to traditional sequential construction.

The concourse itself will be assembled in nine large, prefabricated segments, each delivered with major systems such as mechanical, electrical, and plumbing systems, as well as lighting and interior
finishes, already installed.

Once transported to the site and secured, final systems connections, joint finishes, furnishings, and finishing touches will be completed on-site, seamlessly bringing the terminal together.

More airports are considering this approach where construction activity across an already busy facility is a significant challenge.

SAFETY AND LOGISTICAL BENEFITS

Modular construction delivers substantial safety, efficiency, and logistical advantages over traditional airside methods as by relocating much of the work to the off-site mod yard, crews spend less time airside, reducing exposure to aircraft, traffic, foreign object debris, and associated risks to both workers and airport operations.

Materials, equipment, and rentals can be delivered without the constraints of airport security, and the controlled environment supports the high precision needed for seamless module-to-module connections.

From a logistics standpoint, the mod yard provides more staging space and eliminates restrictions on hot works and welding common to airside environments.

Modular construction also enables resource levelling. In traditional projects, manpower demand fluctuates sharply between phases; with a mod yard, different phases can progress simultaneously.

When airside work slows, resources can be shifted to yard activities, improving overall productivity.

Positioning the mod yard beyond the restricted zone of the airport further streamlines scheduling. Work is no longer limited to badged personnel, onboarding can begin immediately while the three-week badging process runs in parallel, and workers save roughly one hour per day otherwise lost to security screening — equivalent to 10% of a 10-hour shift.

On a recent UK project, involving the construction of a new pier, the main contractor reported a 200% increase in labour efficiency with modular methods, alongside fewer site incidents and reduced operational impacts.

THE FUTURE OF THE GLOBAL AVIATION CONSTRUCTION INDUSTRY

As we gain more experience in using modular construction at airports, we are learning how to maximise the benefits and navigate the limitations of this construction type.

For large, complex airport projects, the chief benefit of large modular construction is that existing gates remain operational longer and new gates are opened sooner.

The possibilities around greater module size and higher state of module completion (e.g. modules including glazing, lifts and escalators, ceiling and floor finishes) are evolving and our process is refined with every module completed.

The lessons learned in this process further increase the efficiency of large modular construction.

As more airports upgrade their ageing facilities, modular construction is poised to become an increasingly important tool in aviation infrastructure development, delivering a win-win for construction and operation.

About the author

Jonathan Massey, is managing principal and aviation sector leader at Corgan (www.corgan.com), which was ranked as the No.4 architecture firm in the US by Building Design+Construction in 2024/2025.