The October 2005 issue of "Architectural Record" magazine contains two Zahner projects and one is the new DFW Terminal D project.

This article focuses on the design of Terminal D of the Dallas/Fort Worth (DFW) airport in Texas. The design by HNTB, HKS and Corgan Associates consolidates international arrivals and departures. 

The international flights at DFW were previously scattered in three terminals, making international security difficult. The airport adopted a scheme that modified the stretch arc which normally defines airport terminals, and instead defined the airport's terminal into a still single-loaded, squared-off U shape.

A project of this size requires a large team effort. Several architecture teams were involved on various aspects of its design, including HNTB, HKS, and Corgan. Zahner worked under the team to digitally defined and developed the architectural surface on this Terminal D roof. 

DFW Airport Terminal D.
DFW Airport Terminal D.

A custom-designed structural system was developed and installed 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 curvilinear form, referencing a torus shape. Zahner developed a sloping roof system which provided a gentle curvature. 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.

That 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.