How Silicone Coatings Supported Modular Construction at One of the World’s Busiest Airports

Dallas Fort Worth International Airport (DFW) has long been a hub of innovation and efficiency - one of the busiest airports in the world and the largest carbon-neutral airport in North America.

As part of its major expansion to support passenger growth, DFW added a new terminal and expanded existing ones.

With millions of travelers moving through the airport each year, shutting down or disrupting operations for construction wasn’t an option. The solution was modular terminal construction, designed and assembled off-site, then transported and installed during non-peak hours.

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Building for Efficiency with Silicone

This fast-paced, high-volume project required materials that could keep up with complex scheduling and multiple trades on-site.

Elemax™ Air & Water-Resistive Barrier (AWB) Coating and UltraSpan™ Pre-Cured Weatherstrip were selected to meet these needs.

Unlike many AWB coatings that degraded under prolonged exposure to sunlight or weather, Elemax AWB Coating was designed to handle tough conditions without losing performance. Its primerless, one-coat application became rain-ready in just 30 minutes and was able to be installed in temperatures as low as 0°F (-18°C) and as high as 150°F (66°C). This gave contractors flexibility to work efficiently without worrying about reapplication or weather delays.

UltraSpan Pre-Cured Weatherstrip added another layer of protection, providing a watertight seal across a variety of substrates while maintaining full compatibility with the Elemax AWB system.

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Seamless Coordination on a Complex Build

On a job site with so many moving parts, flexibility and reliability were essential. KEMCO, the project applicator, noted how Elemax AWB Coating’s consistent performance allowed for smooth coordination with other trades and modular assembly timelines.

The silicone-based coating not only protected against water intrusion but also created a breathable, permanently flexible barrier that moved with the building. This helped prevent long-term water-related issues such as mold, corrosion, and rot—while helping to contribute to energy efficiency improvements.

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Setting New Standards for Terminal Construction

By combining innovative modular building methods with the proven performance of silicone air and water barriers, DFW expanded its capacity without slowing down operations.

This project demonstrated how silicone technology could meet the demands of modern construction - delivering durability, speed, and energy efficiency for one of the most critical transportation hubs in the world.

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Project Credits

Project Applicator: KEMCO

Products Used: Elemax™ Air & Water-Resistive Barrier Coating, UltraSpan™ Pre-Cured Weatherstrip