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.
The new Terminal D at the Dallas Fort Worth Airport is the largest square-foot project completed to date using Zahner's Inverted Seam roof and facade system. The new terminal was built to give international travelers a lasting positive impression of their arrival and departure from the United States. The building envelope for this work includes approximately 500,000 square feet of surface covered with 11 acres of stainless steel cladding for the roof. Just over two miles of gutter and five miles of fascia panels adorn the roof. The entirety of the building envelope metal system was included in the scope for the Zahner team. Zahner worked with the architects at HNTB, Corgan Associates, and HKS, to complete this vast project.
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.