Austin International Airport (AUS) West Gate Expansion

The Project

The West Gate Expansion at represents a critical initiative for the Austin-Bergstrom Airport Expansion and Development Program (AEDP), designed to meet the airport’s growing passenger and operational demands. The project adds approximately 84,500 square feet across three levels, including a new mezzanine, expanded passenger amenities on the concourse level, and additional airline support space at the apron level. A total of 12 gate-boarding bridges are being replaced in addition to 3 new gates, enhancing the terminal’s capacity to accommodate future growth.

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The Structure

The high roof truss was designed with a focus on maximizing efficiency, aesthetics and structural integrity while minimizing complex construction. CAST CONNEX custom and standardized cast steel nodes enabled precise bolted connections that eliminated extensive field welding, improved constructability, and enhanced both structural integrity and architectural expression. Their use streamlined fabrication and delivered resilient, repeatable solutions within the complex roof geometry.

This casting-based approach enabled pinned and field-bolted solutions to eliminate the need for field welding, improving on-site constructability while elevating the safety, durability, and visual quality of the exposed structure. This solution also enhanced structural integrity by minimizing tolerance-related fit-up issues, while simultaneously supporting the architectural intent of a visually expressive roof structure.  

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By leveraging advanced design and engineering techniques, CAST CONNEX introduced innovative field-bolted casting solutions that significantly streamline the construction process:

Modular Assembly: Cast steel connections facilitated modular assembly of the trusses, which were precision fabricated in a controlled shop environment off-site.  These truss modules arrived ready to be bolted together on the ground and then lifted into place as complete segments. This streamlined approach accelerated the project schedule, reduced on-site disruptions at the busy airport, and delivered a controlled, efficient, and cost-effective construction process.

Elimination of AESS Field Welding: Utilizing cast steel solutions in the engineered field-bolted connections completely eliminated the need for field welding in the high roof framing altogether. This approach not only reduced on-site labor and improved safety, but also enhanced overall aesthetics by delivering clean, uniform connections. This resulted in a visually striking structure that enhanced the architectural design without compromising strength or functionality.

Optimized Structural Performance: CAST CONNEX streamlined the design by incorporating multiple connection types into simplified components, resulting in smoother integration during construction and improved long-term durability.  The castings also addressed complex loading conditions—including fixed field-bolted column connections which enabled a stiffer overall structure and controlled building drift, which was critical for the performance of the curtain wall system.  Harnessing the geometric versatility of cast steel, the connections also resolved common tubular structure issues, such as local wall buckling and shear-punching failures. By designing cast steel nodes with strategically reinforced regions and optimized geometry, the system achieved enhanced structural reliability and overall performance.

Streamlined Fabrication and Risk Management: Leveraging the geometric freedom of cast steel, complex tubular connections were simplified into engineered components, converting intricate cutting and fit up into effortless, butt-splice welded joints. CNC-machining ensured precision connection tolerances, further simplifying fabrication, improving constructability, enhancing reliability, and accelerating assemblly while minimizing the risk of fabrication errors and costly on-site rework.

The West Gate Expansion demonstrates how cast steel solutions can combine structural ingenuity, efficient construction, and architectural expression. It delivers a resilient, passenger-focused terminal that balances engineering innovation with visual impact, providing a model for high-performance, constructible, and aesthetically striking aviation infrastructure.

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