Portland International Airport

Construction occurred above an operating airport terminal, limiting allowable shutdowns and increasing safety and operational constraints.

The expansive, curved roof geometry introduced complexity in fabrication, transport, and placement of long-span structural elements.

The roof combined sustainably sourced timber with steel framing, requiring careful stability control during temporary and permanent conditions.

Tight site conditions required efficient movement and positioning of oversized roof components within a constrained footprint.

The roof was segmented into prefabricated cassettes, each approximately 80 feet by 170 feet, allowing work to proceed away from the terminal.

Engineers developed adjustable temporary shoring and stability plans to support timber and steel components during prefabrication and erection.

Self-propelled modular transporters moved completed cassettes from the laydown yard to the terminal, minimizing on-site handling.

Engineered launch procedures used jacking, temporary locking, and sequencing to safely position each cassette onto the supporting Y-columns.

Modular installation eliminated months of heavy construction above the terminal, reducing risk to passengers and staff.

Off-site prefabrication and controlled installation sequences significantly reduced worker exposure in active terminal areas.

Prefabrication enabled faster roof installation once cassettes were delivered to the terminal footprint.

Each cassette arrived with structural, mechanical, and electrical components integrated, streamlining final connections and finishes.