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Work Begins On San Antonio Airport Terminal

Construction has begun on the $1.2 billion third terminal at San Antonio International Airport, part of a $2.5 billion expansion plan to accommodate rapid growth. The project, focused on enhancing passenger experience and economic development, is set to be completed by mid-2028. Hensel Phelps is managing the construction, creating new jobs and engaging local firms in the process.

Wed January 22, 2025 - West Edition #2
Irwin Rapoport – CEG Correspondent


An excavator takes the first step in preparing the new terminal site.
Photo courtesy of San Antonio International Airport
An excavator takes the first step in preparing the new terminal site.
An excavator takes the first step in preparing the new terminal site.   (Photo courtesy of San Antonio International Airport) An excavator breaks ground on the new third terminal at San Antonio International Airport.   (Photo courtesy of San Antonio International Airport) A Bobcat T595 compact track loader and Volvo excavator are lined up at the future home of a new third terminal.   (Photo courtesy of San Antonio International Airport) Two JCB 510-56 telescopic handlers flank the site of the Dec. 10, 2024, groundbreaking ceremony at San Antonio International Airport.   (Photo courtesy of San Antonio International Airport) Another view of the groundbreaking site.   (Photo courtesy of San Antonio International Airport)

Hensel Phelps Construction crews broke ground on Dec. 10, 2024, on the San Antonio International Airport's (SAT) $1.2 billion third terminal, a key element in a $2.5 billion expansion and improvements plan approved in 2021.

The city-owned airport is experiencing rapid growth, and the terminal project is part of the ELEVATE/SAT airport expansion and improvement plan.

"The San Antonio International Airport is serving record-breaking passenger travel and has become a focal point for economic growth in the region," according to the project web page. "ELEVATE/SAT represents the design and creation of an elevated airport experience that our community deserves. From improvements to facilities and runways and the development of a world-class terminal complex, ELEVATE/SAT is taking our airport to new heights."

Photo courtesy of San Antonio International Airport

In November 2023, Jesus Saenz, the director of airports for the San Antonio Airport System (SAAS), explained how the airport's operations are growing rapidly.

"This year has been beyond incredible for SAT," he said. "From new nonstops taking us to 45 domestic and eight international destinations — and more travelers than ever choosing SAT — we are making history every single day. As we start 2024, we'll enter the pre-construction phase — right on track as we expand our airport for everyone in San Antonio and our visitors from around the world."

The construction of the new terminal is part of the Terminal Development Program (TDP), which will guide the future development of the airfield, terminal facilities, ground access and support infrastructure over the next 20 years. TDP is the cornerstone of ELEVATE/SAT, the largest capital improvement plan that the city of San Antonio has ever undertaken.

"SAT continues to rise to the occasion and meet the demand of our region's expansion," Mayor Ron Nirenberg said. "This new terminal will help the airport accomplish even more continued growth, fostering the development of important connections and business opportunities for our region. It will strengthen our position as a hub for global business, develop key industries that are economic drivers for our region, connect our local companies to new markets and bring in visitors who will contribute to our local economy."

The initiative is based on these elements: accommodating current and future air service expansion; recognizing that increasing congestion in aging facilities is not acceptable; realizing that modernization is essential for passenger growth and retention; enabling a business travel and tourism-driven economy to which SAT contributes approximately $5 billion annually; and providing an outstanding first and last impression of the city and region.

The city pointed out that the new terminal is required because SAT is one of the nation's fastest-growing medium-sized airports.

"This project represents not just the future of our airport but also our commitment to meeting the needs of growing international and domestic passengers," Saenz said. "You're going to see a terminal you've never seen before. It's going to be first-class."

The new terminal, to be delivered in mid-2028, will have 850,000-plus sq. ft. of space, including 41,000 sq. ft. of new concession space and 29,000-plus sq. ft. of club lounge space.

The design calls for up to 17 domestic and international gates to accommodate projected growth through 2040. The larger gate hold rooms will improve passenger comfort and the Riparian Paseo entry and indoor courtyard will enhance the sense of place and River Walk feel.

There will be a central passenger screening area to provide all-access passes to retail and concessions, a modern federal inspection station for expanded international air service, and roadway improvements to improve traffic flow and remove congestion.

The expansion plan also provides for new ground load facility amenities, such as three new ground gates south of Terminal A; an integrated federal inspection station for international arrivals; two levels of seating areas for passengers; and dedicated charging stations for electronic devices, workstation areas, high tabletop stations and a lactation room, as well as additional food and retail options.

Photo courtesy of San Antonio International Airport

The expansion will impact the state's construction sector. According to SAT, building the new terminal will generate 16,000 jobs.

In November 2023, SAT selected Hensel Phelps to serve as the construction manager at risk, noting that the firm is known for its general contract and construction work for the planning, building and management of landmark buildings.

"We were thrilled with the quality of the proposals the airport received," San Antonio City Manager Erik Walsh said. "Hensel Phelps is the nation's largest aviation contractor and has developed some of the best terminal projects in the country, including Nashville, Seattle, Los Angeles, Tampa and Orlando. Hensel Phelps will work closely with our master architect team of Corgan/Lake Flato to advance the design of the new terminal.

"We chose the construction manager at risk delivery method," Walsh added, "to minimize risk to the city and airport and maximize opportunities for small, local and disadvantaged business enterprises to participate in the project. Hensel Phelps will be required to bid out approximately 85 percent of the work, which creates a lot of potential bites at the apple for other firms."

SAT already is a hit with airlines.

In October 2024, the city signed a 10-year airline use lease, along with a five-year option. To handle increases in passengers, SAT is constructing a new ground loading facility at Terminal A that will add three ground load gates, new passenger gates and overnight aircraft parking.

The new terminal is being designed by Corgan Associate Inc., and Lake Flato, selected in March 2023 as the master architect team for SAT's Terminal Development Program. That contract is valued at $30 million.

Robin Schmerber, SAT's strategic communications manager — development, stressed that a key design challenge is "ensuring we can accommodate project needs while operating the airport without impact is always a challenge. A huge benefit of using a CMAR is that the contractor is embedded early on in the design process, so that both teams are aligned to create the best possibleoutcome."

"I'm looking forward to continuing to work closely with both nationally recognized firms to make the new terminal complex a place to be proud of," said Tim O'Krongley, the deputy director of San Antonio Airport System, who leads the terminal development team. "They will incorporate our vibrant, unique and welcoming San Antonio culture into the design and construction of the new facilities through the application of the design standard manual and the city's public art program. All of these architectural and engineering services for our 17-gate new terminal facility will support air service growth over the next few decades."

The new terminal should have a lifespan of approximately 50 years. Construction materials are still being scoped.

The new terminal site is at the west end of Terminal B and will be connected to it through a short walkway. The site encompasses an existing parking lot.

At this moment, the site is not isolated from ongoing airport operations.

"However, the plan is to eventually have the construction site be landside so as to not impact airside ops in any way," Schmerber said. "Groundbreaking was on Dec. 10 and so we are currently in the site mapping and surface work phase. No structures are included in the site plan so there won't be any demolition other than to pavement."

All underground infrastructure beneath the terminal will be new and be connected to the existing infrastructure.

The construction phasing is being finalized, with crews from Hensel Phelps on-site.

At this point, they have focused on airport operational concerns, site capture and enabling work milestones.

The work has its challenges.

"[We are] operating in the airport space," the Hensel Phelps team noted. "[Another is the] ongoing haul-off of concrete apron material through the airport roads without impacting traffic."

Planning is essential to avoid conflicts.

Photo courtesy of San Antonio International Airport

"[This requires] constant diligent coordination with airport operations, 24-7 airport sweeper, escorts crews, and night work, when possible," the Hensel Phelps team said. "Airport aviation is a main commercial construction focus for Hensel Phelps. As such, we work in many airports complex projects that require ongoing coordination and passenger experience focus. Every airport project has similarities and differences."

It took a week for the company to set up the demolition equipment and mobilize operations.

And there is much to do to prepare for full-scale operations.

"It will take over a mile of perimeter secure fencing to allow for the construction work activities, and it will require significant excavation volume to allow for permanent facility space to be installed," the Hensel Phelps team said.

At its peak, there will be 600-700 Hensel Phelps and subcontractor personnel on-site.

"We are in ongoing subcontracting procurement efforts," the Hensel Phelps team said. "Some current firms involve but are not limited to JR Ramon Demolition, AK Fuquay, Alterman Electric, Flatiron and many others." CEG


Irwin Rapoport

A journalist who started his career at a weekly community newspaper, Irwin Rapoport has written about construction and architecture for more than 15 years, as well as a variety of other subjects, such as recycling, environmental issues, business supply chains, property development, pulp and paper, agriculture, solar power and energy, and education. Getting the story right and illustrating the hard work and professionalism that goes into completing road, bridge, and building projects is important to him. A key element of his construction articles is to provide readers with an opportunity to see how general contractors and departments of transportation complete their projects and address challenges so that lessons learned can be shared with a wider audience.

Rapoport has a BA in History and a Minor in Political Science from Concordia University. His hobbies include hiking, birding, cycling, reading, going to concerts and plays, hanging out with friends and family, and architecture. He is keen to one day write an MA thesis on military and economic planning by the Great Powers prior to the start of the First World War.


Read more from Irwin Rapoport here.





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