As the largest single infrastructure project in Kansas City history, this $1.5-billion, 1.1-million-sq-ft design-build effort replaced a three-terminal facility to streamline airport operations and improve passenger experience. The two-story H-shaped structure sits next to a 6,200-space parking facility. Designed with expansion in mind, the terminal opened with 40 gates and the capability to add 10 more gates in the future.

The project team collaborated through six design iterations to achieve $38 million in cost reductions while preserving the project scope and design intent.

Given the terminal’s structural systems, consisting of steel and cast-in-place concrete, the project team divided the massive scopes between two trades to limit the need for additional workers and steel lead times. Prefabrication across multiple trades also helped, including unitized curtain wall, precast panels and bathroom components.

A phased construction plan divided the building into 17 sections along the structure’s expansion joints. Construction ended more than two months ahead of schedule in February 2023.

The 800-ft-long headhouse, or check-in hall, features a wide front cantilevered overhang supported by 25 65-ft-tall Y columns and 115-ft-long box beams above an elevated roadway. A precast wall in front of the headhouse went up before the precast road-support columns and the roof’s steel Y columns, which were assembled on site and lifted as one piece.