The new airport terminal complex is a $1.8 billion project that includes a world-class terminal building and 16 gates. This project is a true design-build marvel that brought the owner, designer, contractor, and manufacturer together to design and build the new construction. The manufacturer developed the details during the pre-construction phase and successfully delivered engineered column covers complying with specified design and material requirements while also providing point accessibility for easy maintenance.
The manufacturer provided 274 uniquely shaped, highly custom column covers comprising more than 5,000 column skins, as well as 700 linear feet of beam enclosures throughout multiple floor levels, including ticketing, baggage claim, international security checkpoints, customs, gate areas, and exteriors. Each column cover comprised multiple stacks made of multiple materials, including 16-gauge galvanized steel skins with factory-applied AAMA 2604, 2605 powder coating finishes and 16-gauge, type 304 stainless steel bases.
One of the challenging aspects of the design was to maintain tight tolerances during fabrication and installation so that the radiused skins of the multiple stacks perfectly aligned to create a monolithic appearance. Many column covers were traditionally installed in a vertical condition, while some columns were a combination of sloped to vertical, with heights spanning over 80 feet tall. Additionally, the column cover design served both form and function and required the skins to include various cut-out configurations based on MEP layouts that were meticulously coordinated during the submittal and fabrication process. Hinged doors with secure access were custom-engineered and fabricated to be part of the columns.
A mockup column cover was fabricated and shipped to the job site for the design team’s review and approval. Upon receiving approvals, the installing contractor and the manufacturer worked as a team to develop a project plan. The project was broken down into logical phases that would help both parties create a steady workflow in the plant and at the job site. Communication was key to ensuring there were no setbacks during material release, engineering, programming, fabrication, packaging, and shipping.
Other challenges included supply chain issues after the pandemic, which were overcome by the manufacturer working proactively with the raw material suppliers early in the project. All materials, including sheet material, nuts, bolts, and gaskets required to complete the job, were procured in advance to ensure there were no material shortages during production. The shortage of wood resulted in an innovative crate design by the manufacturer that could securely hold more column skins utilizing less wood. This new design of crates also ensured maximum occupancy of the truck space, minimizing the number of trucks with reduced environmental footprint and freight costs for the project.
Installing various MEP devices and maintaining tight tolerances to achieve the aesthetics of the design required high craftsmanship that could not be achieved without the expertise of the installing contractors on this project. It is the true partnership of the installing contractor and manufacturer that resulted in the successful delivery of this major project and makes it worthy of the CISCA 2023 award.
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