McCarthy completes $310 million concourse for Sky Harbor Terminal 4

McCarthy Construction Companies Inc. recently completed construction of the eighth and final concourse of Terminal 4 at Phoenix Sky Harbor International Airport, which includes the addition of eight new gates serving Southwest Airlines passengers.

Terminal 4 at Phoenix Sky Harbor International Airport is the airport’s busiest terminal and handles over 80% of passenger traffic annually. The airport handled nearly 39 million passengers in 2021, and during peak periods the existing gates in Terminal 4 often reached capacity. The addition of eight new gates brings Terminal 4’s total to 92 gates. The new concourse, designed by SmithGroup in partnership with Corgan, is located on the southwest corner of the terminal next to low concourse D.


READ ALSO: The $260m Sky Harbor project will be the first to benefit from the Infrastructure Act


“As America’s Friendliest Airport®, our goal is to provide an exceptional customer experience for our travelers,” said Director of Aviation Services Chad Makovsky. “As Phoenix Sky Harbor continues to grow, it is important for us to provide facilities and services that match our customers’ needs. We are delighted that this new concourse does just that, offering a variety of customer amenities, from charging stations at every seat to technology designed to improve accessibility and comfort for everyone traveling through our airport.

The total project added or remodeled approximately 275,000 square feet of space, with the addition of 161,500 square feet representing the eighth and final concourse and Terminal 4 connecting bridge. Included approximately 137,000 square feet of configured concourse with apron and passenger levels; in lobby space, approximately 25,000 square feet of outdoor space for retail and food and beverage concessions; a new 24,000 square foot transfer bridge now connects the South Concourses to the North Concourses on the west side of Terminal 4.

The project also included terminal processor improvements, expansion of the existing D security checkpoint, additional ticket counters and a new baggage handling system to support the new gates and associated travellers. Approximately 113,000 square feet of space was also remodeled with the project.

“It was essential that all ongoing airport operations at the terminal continue with minimal disruption during the three years of construction of this project. Fortunately, our McCarthy teams are well versed in managing construction projects at busy airports, having successfully completed the award-winning PHX Sky Train® extension to Terminal 3 and terrazzo flooring upgrades throughout Terminal 4,” said Brandon Moon, Vice President, Project Director. , for the Southwest McCarthy area. “This latest hall in Terminal 4 has been designed with larger waiting areas, which are surrounded by electrochromic glazing to create a comfortable environment for passengers. Every part of the new hall has been designed and built to provide an exceptional experience for passengers. Sky Harbor passengers.

The project is pursuing LEED Silver certification through the US Green Building Council. Approximately 14,000 square feet of electrochromic glazing, a glazing system connected to low-voltage wiring and control systems, tints the windows based on outside temperature and sun angle. Technology is making the passenger and employee experience more comfortable in the lobby, and that’s a first for Sky Harbor. Project planners implemented further environmental savings by reusing foundation and slab materials from the old 1960s buildings. Concrete was crushed and used on site for backfill, obviating the need to import additional materials and the reinforcing steel was completely recycled.

The project design reinforces connections to place through moments of engagement with the landscape, the sky, the city and the PHX Sky Train®.

“We placed a high priority on creating views of distant mountains and bringing in abundant daylight, choreographed to provide patterns of light and shadow as the sun moved. throughout the day,” said John Tran, vice president and chief design officer at SmithGroup. “The new hall is grounded in its place and context, as part of the evolving Sky Harbor campus as well as its home in Phoenix and the Sonoran Desert.”

The Sky Harbor Terminal 4 project also maintains a distinctive tradition for the airport.

“We continued the theme of art installations to support Sky Harbor’s reputation as a major center for public art,” Tran said.

“Leading the design of Sky Harbor’s interiors, Corgan’s aeronautical expertise seamlessly integrated additional efficiencies for airside operations without sacrificing an elevated passenger experience, honoring a sense of place with human-centric amenities and a destination that celebrates local materiality, art, culture and geology. of the Arizona landscape,” said Thomas Lusk, project design manager at Corgan.

Construction of the facilities began in May 2019 and significant construction milestones were reached during the pandemic when passenger numbers plummeted. The first flights from the new hall are scheduled for later this summer.

In addition to expanding the airport’s busiest terminal while it was in operation, notable features of the project include:

• 1.5 miles of conveyor belts for the baggage handling system installed as well as 1,400 linear feet of jet fuel pipeline;

• Construction of four tunnels and two bridges; by building tunnel structures for baggage transfers, the team was able to remove the need for an expensive additional basement structure;

• 49.6 million pounds. of concrete ; 1.9 million pounds. rebar; 92,000 square feet of exterior metal panels and 56,000 square feet of terrazzo flooring

The main contractors for the project were G&S Airport Conveyors, DP Electric, Karber Corp., GrayWolf, Kovach, Rhino and E&K. Karber Corp. and Rhino are designated City of Phoenix Small Business Enterprises.

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