Key Project Experience

Narrative about key project experience

Flatiron Turner JV

  • Concourse A-West & B-West Expansion, Denver, CO

    As part of DEN's concourse expansion program, Flatiron is partnered with sister company Turner Construction (TFN) to build and renovate 620,000 SF of total expansions for Concourses A-West and B-West. Scope includes the construction of 16 new gates, new de-icing facilities at the west end of each concourse, and new in­ground jet-fuel pits for all new gates. Flatiron performed demolition, utility relocation, drainage installation, and the replacement of various airfield structural sections, new waterproofing, concrete sealers, and new expansion joints, as well as coordination of the installation of new domestic water services, jet fuel hydrant pits, and new ramp and taxiway lighting. To accelerate the installation of plumbing in the basement at Concourse A-West, Flatiron developed a plan to re-sequence the work after the space using innovative means and methods including switching to LNG powered equipment, adding the use of conveyors, and developing an alternative access plan. Flatiron developed several pavement mix designs in order to maximize the scope of the project, including collaborating with DEN to mock-up and test several mix design options, ensuring the proposed mix designs met or exceeded DEN's expectations.

  • Terminal B, Airside Concourse, Sacramento, CA

    Known as “Big Build,” the capital improvement plan at Sacramento International Airport is the largest CMR modified design-build contract executed in Sacramento County’s history. The terminal positions the airport for long term growth, with future expansion incorporating additional gates and converting Terminal A to an airside concourse linked to the central terminal by a second APM. The JV provided construction management services for a 316,000 SF project consisting of a new 19-gate passenger airside concourse with an international arrivals facility replacing Terminal B. Recognizing the constraints of building the new Central Terminal B Airside Concourse within an existing terminal at the busy airport, the design-build team presented a construction plan to deliver the project to the Sacramento County Airport System in two phases, saving time and money.

  • SAN Terminal 1 Replacement, San Diego, CA

    As a Joint Venture, Flatiron and Turner Construction are delivering the San Diego Regional Airport Authority’s Terminal 1 Replacement at San Diego International Airport. As part of the long-term airport development plan, which includes a multi-faceted infrastructure and facility development program, the Terminal 1 Replacement is the centerpiece of supporting the region’s increased air travel demand through 2035.

    This $2.27B progressive design-build project includes the design and construction of a new 1.2 million-square-foot Terminal 1, a new parking garage, relocation of the existing taxiway and construction of a second, a new access road, a new administration building, and reservation of a site for a future transit station.

    SOW: The scope of work includes the terminal and roadways portion of the airport development plan including phased construction of the new Terminal 1 building with up to 30 gates, aircraft boarding bridges, a new entry, enhanced airport circulation, arrival and departure roadways, pedestrian bridges, demolition of buildings, surface features, utilities (new and relocated), storm drainage collection, storage and transmission facilities and existing central utility plant upgrades.

Turner Construction

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Flatiron Constructors, Inc.

  • Dallas Love Field Runway 13R-31L & Taxiway C Phase 1 Reconstruction, Dallas, TX

    Recently awarded ENR Texas & Louisiana’s 2023 “Project of the Year”, the 8,800-ft-long runway’s complete reconstruction meets FAA design criteria while enhancing airfield safety and improving airfield efficiencies. Scope of work included pavement demolition, reconstructing a portion of a parallel taxiway, new connector taxiways to the runway, upgrades to storm drainage and the runway safety areas as well as new lighting. Originally built in the 1960s, Love Field’s main commercial air carrier runway saw its last rehabilitation in 1990. It’s been in service far past its 20-year design life, with pavement evaluations indicating that the runway had deteriorated past the point of repair. Among the project’s operational benefits are fewer runway shutdowns thanks to upgrades to adjacent taxiway, drainage, electrical and communications infrastructure. To counteract impacts from Hurricane Ida on the supply chain, the project team held a partnering session to develop a plan of action. After identifying additional sources of cement and fly ash outside of the local market, the client decided to pay for transportation and delivery costs for materials that came from as far away as Chicago to mitigate schedule delays. Extra crews also came in from Houston to assist with concrete paving. Crews paved more than 436,000 sq yd of concrete, with 1% removed and replaced due to quality or craftsmanship issues. The runway also received a 99.6% within limits rating, an FAA specification payment deduct mechanism for concrete paving based on quality. Approximately 92% of the base course was recycled existing pavement, while finer material generated through the crushing process found use as pipe bedding. Repurposed demolition waste became temporary haul roads, and 85% of the earthwork saw reuse, reducing hauling efforts. In total, the project team reduced a projected seven-month delay to four months and cut two months from the overall project schedule to reach substantial completion in October 2022.

  • Flatiron has successfully delivered over 20 airport projects in the state of Texas within the last seven years, including:

    • Dallas Love Field (DAL), Runway 13R-31L and Taxiway C Phase 1 Reconstruction (highlighted above)

    • Dallas Love Field (DAL), Crossfield Taxiway

    • Dallas / Fort Worth International Airport (DFW), Northeast End Around Taxiway - Package 1

    • Dallas / Fort Worth International Airport (DFW), Taxiway Foxtrot Rehabilitation

    • Dallas / Fort Worth International Airport (DFW), Taxiway Mike South Rehabilitation

    • George Bush Intercontinental Airport (IAH), Rehabilitation of Taxiways WA and WB

    • George Bush Intercontinental Airport (IAH), Reconstruction of Taxiway NA

    • George Bush Intercontinental Airport (IAH), Mickey Leland International Terminal, Terminal D

    • Ellington Airport (EFD) / IAH / William P. Hobby Airport (HOU), Miscellaneous Airfield Repairs

    • Ellington Airport (EFD), Axiom Space, Phase I

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