Dallas Fort Worth Airport

Dallas Fort Worth Airport, Terminal D

The new Terminal D at the Dallas Fort Worth Airport is the largest square-foot project completed to date using Zahner's Inverted Seam™ Roofing System.  The new terminal was built to give international travelers a lasting positive impression of their arrival and departure from the United States.   Zahner worked with the architects at HNTB ,  Corgan Associates , and HKS , to complete this vast project.

Aerial view of Terminal D while landing Original photograph by Justin CozartZahner digitally defined and developed a custom-designed structural system to maintain the exact shape of the architect’s model. The corrugated metal decking system installed under our roof could only provided a facetted form. The owner and the architect wanted a torrus shape. The entire roof was then clad with 22 ga stainless steel, Inverted Seam™roof panels. Zahner custom fabricated and installed all of the gutter and fascia systems that were incorporated into the surface.


The project features approximately 500,000 square feet of surface covered with 11 acres of stainless steel roofing. Just over two miles of gutter and 5 miles of fascia panels were also part of Zahner’s scope.

Energy Efficiency

The Zahner Inverted Seam™ Roof is part of the total low-energy solution for the project, reducing the cooling costs by more than 90 percent during peak electrical demand hours.

Zahner field workers during construction

The Terminal D development program includes design of the airport’s central thermal storage tank, a structure that utilizes less expensive electricity at night to create a store of ice to cool the terminal during daytime hours when rates are higher. The project was reviewed by the Clean Airport Initiative team of experts to evaluate incorporated features of sustainable design and to use it as a case study for upcoming guidelines for sustainable airport design.

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