Marble Limestone Shines in John Wayne Airport Terminal

John Wayne Airport’s (JWA’s) new Terminal C opened to passengers on Nov. 14, 2011. Constructed by McCarthy Building Companies and designed by Gensler, the terminal increases JWA’s capacity from 8.4 million annual passengers to 10.8 million. It also provides the airport with the ability to operate international flights. The $211.5 million facility was part of the $543 million Airport Improvement Program.

Serving as the general contractor, McCarthy began construction on Terminal C in August 2009. The design of Terminal C draws heavily from the distinctive features of the existing Riley Terminal, creating a seamless experience throughout the entire airport complex. The building’s exterior skin incorporates masonry, plaster and stone, along with glass and metal panels similar to the existing structures. The interior features barrel-vaulted ceilings resembling a fuselage, an abundance of windows and skylights, a soft, neutral color palette and natural marble limestone.

Called Jura stone, the natural stone is featured throughout the walls and floors in all terminals. Its most distinguishing characteristic is the natural quartz veins and variable fossils which are visible on the beige background. The marble was mined in quarries in Germany and cut, polished and fabricated in Italy, ensuring the correct color and precise and clean lines that make up this beautiful design treatment throughout the terminals.

Tchapadarian explained that one of the project’s most unusual and complex features was installing the barrel-vaulted roof on the Terminal C concourse. About 26 construction workers completed the roof installation by first pouring 1,080 cubic yards of light weight insulating concrete, then carefully installing about 2,100 metal roof panels. Much of the work was conducted atop the 60-foot-high structure, and the process took six months to complete.

In order to reduce errors in the field, Building Information Modeling (BIM) was used to create a 3D model of the project before construction began. The virtual model helped to detect and avoid any system clashes in advance of construction, which, in turn, reduced construction duration and improved the quality of construction. The project was designed in Revit, and NavisWorks was used for clash detection.

Terminal C also features sustainable elements including an innovative LED lighting system, which provides consistent lighting throughout the terminal. The system requires little or no maintenance for 20 years, and will decrease the energy it consumes by at least 37 percent. Furthermore, Terminal C’s Water Quality Management Plan incorporates environmental controls and specifies the means and methods of pollution control. Environmentally responsible construction was used during the project including: curbing storm water runoff from the construction sites to prevent discharge of pollutants to the storm drains; recycling 90 percent of construction-related materials and waste; and dust mitigation activities to minimize air quality effects during construction.

Parsons of Pasadena, Calif., is the program manager; Arcadis/Pinnacle One of Irvine, Calif., is the construction management firm; Jacobs of Santa Ana, Calif., is the civil and MEP engineer; and IDS Group Inc. of Irvine, Calif., is the structural engineer. The main specialty contractors are: Capparelli/KHS&S of Orange (framing/drywall); Helix of San Diego, Calif. (electrical), A.O. Reed of San Diego (HVAC), and Pan Pacific Plumbing of Irvine (plumbing).