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At most major airports, modernization seemingly comes with a familiar tradeoff: years of construction, closures, and operational disruption. At Los Angeles International Airport (LAX) 鈥� one of the nation鈥檚 busiest and most compact airfields 鈥� that simply wasn鈥檛 an option.

With the 2028 Summer Olympic games approaching, LAX sought to improve aircraft movement efficiency and build new capacity without interrupting daily operations. Conventional construction methods could not meet that challenge. Instead, LAX adopted a bold approach for a U.S. airport terminal: large-scale modular construction, fabricating fully finished building segments offsite and moving them into place between active taxiways 鈥� in the middle of the night.

The result is Midfield Satellite Concourse (MSC) South: a 150,000 ft2, two-level concourse built in parallel workstreams, installed like precision machinery, and delivered months faster than a conventional approach would have allowed.

We spoke with project team members Stuart Brumpton, Principal; Derrick Roorda, Principal; Louisa Phillips, Senior Structural Engineer; and Nicole O鈥機onnor, Structural Engineer, to understand how this unprecedented strategy came together, and what it means for the future of aviation infrastructure.

Modular design: An approach that treats a building as components to be assembled rather than a single edifice, designing it for off鈥憇ite prefabrication and modular assembly. The process is informed by manufacturing principles so that components can be built in controlled environments and assembled efficiently on site.

For LAX, the project demonstrates how modular construction can shift the economics and risk profile of infrastructure delivery 鈥� particularly in compact, high stakes environments where downtime is not an option. 鈥淟AX wanted to build a new terminal to support the significant transformation happening in Los Angeles,鈥� said Phillips. 鈥淲ith the Olympics approaching, there was a clear and present need to ensure the airport’s capacity was being used efficiently. The project began before COVID, paused during the pandemic, and then resumed at full speed with a strong focus on schedule and efficiency while managing the complexity of building within an active airport.鈥�

Why was modular construction the right answer for LAX?

The process offered an option to accelerate delivery while eliminating the downtime typically associated with major terminal projects. The 150,000 ft2 concourse, supporting eight new aircraft gates, was delivered through a method known as Offsite Construction and Relocation (OCR). Each module (roughly 140 feet by 80 feet) included complete curtain walls, interior partitions, partial finishes, and tested rough MEP systems. 

Every three days, a module was transported across LAX’s airfield using Mammoet self-propelled modular transporters, the same specialized machinery used to move bridges and aerospace equipment. This method minimized disruption to live taxiways and dramatically accelerated the construction timeline. In just one month, the entire concourse was assembled.  

We were effectively building foundations at the same time as we were constructing our steel frame. Using modular construction shortened the schedule by up to about six months.

Stuart Brumpton, Principal

鈥淭he concourse was split into nine smaller modules, all built about a mile and a half away from the installation site,鈥� said O鈥機onnor. 鈥淎t night, these modules were transported on specialized modular transporters and installed at their final location. It allowed the airport to remain fully operational, while construction could continue 24 hours a day off site.鈥� The approach also streamlined logistics and broadened access to the workforce. 鈥淎bout 30% of the workforce on this project was local to the LA area,鈥� O鈥機onnor added.

For an airfield that includes densely co-located runways, taxiways, and security zones, off鈥憇ite fabrication was essential. 鈥淭he site was completely landlocked, with almost zero laydown space,鈥� Brumpton said. 鈥淢odular construction really solved that constraint, while reducing risk by allowing parallel workstreams.鈥�

Foundations and utilities advanced on the airfield while structure, interiors, and building systems were completed at a designated area north of LAX’s northern runway complex. When a module arrived, it already carried the precision and quality of a controlled manufacturing process.

Choreography across live taxiways

The boldest decisions were as much logistical as structural. Moving hundreds of tons through an active airfield required choreography precise enough to withstand the scrutiny of nonstop operations.

Transporting 1,000鈥憈on modules across live taxiways required meticulous coordination with airport operations. We planned routes, emergency standoff zones, and even conducted 3D scans of the site to make sure every clearance was understood.

Stuart Brumpton, Principal

Each move condensed risk into tightly rehearsed nighttime windows. By early morning, flight operations resumed with no visible interruption 鈥� just another piece of the terminal quietly in place.

Seismic considerations and sustainability built quietly into the system

Given Los Angeles鈥� seismic profile, our engineers designed each segment with its own lateral system to meet stringent seismic tolerances. Passengers experience light鈥慺illed spaces, intuitive circulation, and a calm acoustic environment engineering designed to disappear above strict seismic realities. 鈥淓ach module had to be structurally independent because of seismic requirements,鈥� said Phillips. 鈥淭hat meant integrating lateral systems like braced and moment frames, which can be challenging architecturally. We worked closely with Woods Bagot to balance structural performance and aesthetics.鈥� Turning each module into a self鈥憇ufficient structural unit ensured resilience during an earthquake, while demanding careful detailing to make those independent pieces operate as a single building once assembled.

While schedule and operational continuity drove many decisions, sustainability was embedded throughout the modular strategy itself. 鈥淲e really minimized the weight of the steel structure so we could move it,鈥� Brumpton said. 鈥淭hat also meant minimizing embodied carbon.鈥� The steel modules were bolted, not welded, allowing them to be disassembled, recycled, or even relocated in the future as the airport evolves 鈥� aligning with circular design principles.

MSC South also exceeded LAX鈥檚 baseline sustainability requirements. 鈥淎ll LAX projects target LEED Silver as a minimum,鈥� Brumpton noted. 鈥淭his project achieved several credits beyond that threshold.鈥� Early integration across disciplines proved just as critical to sustainability as it was to logistics.

鈥淐ollaboration is everything,鈥� said O鈥機onnor. 鈥淓arly engagement with contractors and movers helped optimize the design for transport and assembly, and simplifying module interfaces saved time after installation. Integrating the entire project team from day one is what made this project successful.鈥�

Beyond airports, modular is a new model for complex sites

Although MSC South pushed modular construction into one of the most operationally complex building types, its logic (parallel workflows, surgical installation, adaptable structures) extends far beyond aviation.

鈥淚t fundamentally changes how we think about building,鈥� Phillips said. 鈥淗ere, we built elevated levels off site while foundations were poured. That mindset can work anywhere space and schedule are constrained.鈥�

鈥淢odular construction isn鈥檛 just efficient,鈥� O鈥機onnor added. 鈥淚t鈥檚 transformative 鈥� and it鈥檚 going to influence how we approach many future projects.鈥�

A quiet signal to the industry

MSC South doesn鈥檛 announce itself as modular. Passengers encounter a calm, contemporary terminal; few would guess it arrived prefinished, on wheels, in the middle of the night. But for clients facing fixed deadlines, spatial considerations, and rising sustainability expectations, the project offers a clear takeaway:

Modular construction isn鈥檛 a shortcut 鈥� it鈥檚 a new operating system for building. And one designed to keep airports, and cities, moving.