Project Overview
Located in a significant seismic zone just 12 miles northwest of midtown Manhattan, Teterboro Airport in New Jersey is extremely popular among passengers flying in and out of the New York City metropolitan area on corporate or private aircraft. To replace an aging air traffic control tower (ATCT) that was constructed at Teterboro in 1979, the Federal Aviation Administration (FAA)—in partnership with AECOM, Walsh Construction, and precast concrete producer Unistress Corporation—built a new 157-ft-high ATCT and a two-story, 18,000 ft2 base building consisting of nearly 300 pieces of precast concrete.
Flying High
The new facility was designed with longevity in mind. Thanks to 242 precast concrete wall panels, 22 precast concrete flat slabs, and 12 precast concrete outriggers, the structure is built to withstand high winds, harsh weather conditions, and seismic activity, and will likely be in service for at least the next half-century.
By using precast concrete, the project team achieved enhanced durability, expedited the construction schedule, and increased structural resiliency. “This is a tall, thin structure that’s exposed to wind shear in one of the busiest airspaces in the world,” said Joe Beck III, chief sales officer for Unistress. “To support structural stability and to maintain the accuracy of the building’s electronic equipment, precast concrete was the material of choice.”
The precast concrete outriggers at the top of the ATCT achieve both structural and aesthetic goals. The outriggers, which would typically be made from steel, support the architectural precast concrete cladding for the tower’s exterior and provide structural stability for a catwalk containing the electrical and HVAC equipment needed for the cab (the enclosed area inside the ATCT where controllers operate).
The project used a design-build methodology, and building information modeling (BIM) was a critical tool. “This air traffic control tower utilized BIM to an exceptional degree,” said Beck. “Through the general contractor, all teams coordinated their designs via a federated model. This model was updated daily, facilitating smooth communication among all stakeholders.”
Beck further explained that the precast concrete workflow was centered on the BIM approach. With all the information accessible via BIM, the precast concrete piece tickets and lifting and handling designs were developed directly from the model. Eriksson Sync software was used to execute the complex and intricate geometry in the lifting and handling designs, which could not be modeled accurately in standard design software. This work helped ensure that all precast concrete components were produced, handled, and set in place as intended. Using the BIM analysis, information was added to the model and developed into shop tickets for plant production. By combining the ticketing production with the trades in one model, field installation was accomplished with minimal issues.
Teterboro Airport’s new precast concrete ATCT meets the FAA’s design requirements to improve sightlines and provide additional space within the critical cab area, while also serving as a blueprint for future ATCT replacement projects throughout the United States.
Mason Nichols is a Grand Rapids, Mich.-based writer and editor who has covered the precast concrete industry since 2013. |