The design of Portland International Airport's (PDX) new terminal is driven by 2 key sustainability factors: resistance to earthquakes and the use of locally sourced materials, writes Vince Granato, chief projects officer at the Port of Portland.
The discussion about building a new main terminal at PDX began over a decade ago, in 2011, shifting from whether upgrades were needed to how those upgrades should be made.
Renovations were necessary to increase capacity, flexibility, and resilience, and also presented an opportunity to make the building more sustainable. However, when the people who work at, live near, or pass through PDX were asked what they wanted, their answer was clear: don't change it.
The project team set out with the goal of expanding PDX's size while doubling down on the features that people already loved about the airport.
From forest to flight: the story of PDX's eco-friendly terminal
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Exploring a new approach
When the idea of building PDX's new main terminal out of wood was first proposed, it raised a question: can it be done in a way that's better for our communities?
Typically, lumber is seen as a generic commodity in the construction industry. This makes sense, as most clients just want a single, uniform product.
However, the team wanted to tackle this big project in a unique way. So, they collaborated to not only source the wood locally (which they did), but to do it in a way that creates better outcomes for the regional forests and the people who manage them.
They worked with industry experts to define what success looks like and how to achieve it. They developed 5 custom sourcing paths that prioritize preserving and restoring forest ecosystems, while creating economic opportunities for landowners, sawmills, and fabricators in the region.
Transparent sourcing on this scale had never been done before, and many said it couldn't be accomplished. But enough partners were willing to try and see how much wood could be traced back to its original forest.
It took 6 years of collaboration with sustainable forestry professionals, multi-generational foresters, and mills that were passionate about balancing ecological and economic values in their work.
This was the first attempt of its kind, and it reached targets that no other projects had achieved. In the end, 100% of the 3.7 million board feet came from within 300 miles of the airport, keeping the money in the region.
72% of the wood came from landowners who are FSC-certified or practice ecological forestry. And 30% can be traced back to its original forest – a number that's typically zero for large construction projects.
An engineering marvel
The airport's new roof was constructed using modular timber panels. These panels were built in 18 sections, each weighing about 1 million pounds. They were assembled in a workshop located west of the terminal. Then, during the night when no flights were operating, the sections were transported one by one across the airfield using specialized vehicles.
The roof is supported by 34 steel Y-shaped columns, which replaced 200 outdated seismic columns.
This new design gives the terminal more flexibility to adapt to changes in air travel and improves passenger flow.
The airport is located in a seismic-prone area, so the new roof was engineered to withstand a 9.0 magnitude earthquake.
The Y-shaped columns have seismic isolation bearings at the top, allowing the roof to move up to 24 inches horizontally during an earthquake. The curtain wall attached to the roof is also designed to slide and pivot relative to the structure below.
The curtain wall is a unique feature. During construction, the team had to simulate the weight of the glass windows by pre-loading the roof every 10 feet, then removing the weights to install the glass, similar to a teeter-totter.
This project presented some of the most significant challenges the team of experts, including engineers, architects, and construction professionals, have ever faced in their careers. However, they were able to successfully overcome one technical obstacle after another.
In the beginning of 2025, the last 4 components will be put into position, and the visually striking and earthquake-resistant roof of PDX will be finished.
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Crafting a forest stroll
The decision to build the new PDX almost entirely with wood was intentional, beyond the seismic and sustainability reasons. The goal was to give travelers a sense of place.
Drawing inspiration from the local environment, the architects at ZGF designed the space to feel like a walk in the forest. Wood is an important part of the regional history and landscape, and when travelers arrive at PDX, they'll know exactly where they are.
PDX brings elements of the great outdoors inside the airport, using biophilic design. This means introducing nature and natural elements into the interior to help reduce stress and make people feel more relaxed in the busy environment.
Travelers are surrounded by lush greenery and 72 full-grown trees, creating a mini greenway in the core of the airport.
The carefully placed skylights mimic sunlight peeking through evergreen trees, and scenes of the region's natural landscapes are displayed on 120-foot-wide video screens. It's a unique PDX experience.
Increased space, reduced carbon footprint
An airport is a 24/7 operation, and it takes a lot of energy to move people and goods through the sky. So, the architects and engineers who designed the new main terminal at PDX explored ways to save energy on the ground. Their efforts nearly doubled the airport's capacity while cutting the energy use per square foot in half.
The choices around design and local materials used will reduce the carbon footprint of the project's structure by 70%. Other factors that contributed to the big energy savings include:
- A ground-source heat pump – one of the largest in Oregon – that cuts the heating plant's use of fossil fuels by 95%;
- 50 skylights and a 36-foot-high window wall that illuminate 60% of the terminal with daylight (even under January's cloudy skies), reducing the need for electrical lighting;
- Fixtures (toilets, sinks, and urinals) that require between 15 and 50% less water. Plus, the airport will soon start using its own well water to flush the toilets and urinals, so that by the time 35 million people a year travel through PDX, each visitor will use 50% less water from Portland's potable water supply.
Sustainability was a key factor in the decision to open the main terminal in 2 phases. The remaining 40% of the terminal is scheduled to open in early 2026, marking the completion of the PDX Next project.
The phased approach allowed them to use as much of the old terminal structure as they could, while renovating around 500,000 square feet of the existing structure and adding new construction to expand the terminal.
Between now and the end of Phase 2, the teams are working to build more local shops and restaurants, permanent exit lanes, and meet and greet areas, in addition to moving those final roof cassettes.
Through teamwork and creative thinking with the partners, they're able to do all of this without ever closing the airport.
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