JFK New Terminal One

The project’s critical path began with one of its most technically demanding tasks: erecting steel around the active AirTrain system. With AirTrain service permitted a maximum disruption window of only four months, Banker Steel and NYCC helped engineer and execute a 60-foot-wide by 900-foot-long steel structure with precast envelope to maintain transit operations while construction advanced overhead. This early-phase achievement set the tone for the precision and planning required throughout the build.

At the heart of the terminal is the Headhouse, an architectural and structural centerpiece supported by ten Y-shaped tree columns and sixteen additional branched columns. Each Y-column features a steel quasi-diamond-shaped forged node weighing 85,000 pounds, from which four sloped “branches” extend to support the sloped roof. Erecting these massive elements demanded advanced shoring solutions—met with an in-house system using 40 telescopic towers to stabilize and position the steel accurately.

Working in an active airport environment added a layer of complexity that required exceptional coordination. Crane operations were carefully designed to ensure compliance with FAA and Port Authority guidelines, while maintaining sightlines for the Air Traffic Control Tower. These restrictions demanded precise planning, adaptive sequencing, and responsive execution—all delivered effectively through the collaboration between Banker Steel, NYCC, Thornton Tomasetti, and the broader project team.

The team’s contributions culminated in the topping out of the Headhouse in March 2024 and the East Pier in August 2024—major milestones that reflect the strength of the partnership, the sophistication of the steelwork, and the high standards of safety and scheduling maintained throughout the project.