Most innovative interior glass project

Washington Dulles International Airport main terminal Automatic People Mover Station, CBO Glass

The Automatic People Mover Station is the newly installed subway that services all of the island terminals at Washington Dulles International Airport, Chantilly, Va. As the glazing and metal panel contractor for the Washington, D.C., office of Turner Construction Co., CBO Glass of Alden, N.Y., was involved in the design of the custom train tube enclosure's structurally glazed curtain-wall system, in addition to the innovative decorative glass structures that highlight the new addition to the terminal.

Enclosed with 13/16-inch heat-soaked laminated glass from Viracon, Owatonna, Minn., the train tube features 64 different ceramic frit patterns, consisting of two coated surfaces of overlapping stripe patterns. CBO Glass had to map out each lite's exact position before installation to ensure everything laid out perfectly, says Tony Scaglione, project manager, CBO Glass.

Adding to the difficulty of the installation was the fact that the train needed to be tested for one year before passengers could use it. For CBO Glass, that meant the team had to complete each 420-foot east and west train tube enclosure before the other contractors could even finish pouring the concrete roof. There also was the fact that the tunnel coming in from the west was complete but the tunnel coming in from the east was still under construction.

"Everything had to be laid out exactly at the very beginning for our system to go right, for east and west to meet perfectly," Scaglione says.

Coordination between all contractors was crucial to the success of the project, which was named in ENR Magazine as Project of the Year for Transportation in 2009. "We had to coordinate with Turner ... the rail contractor ... and Parsons Management Consultants as [the] airport owner's representative. We had to make sure that everyone was on the same page," Scaglione says.

The entire Automatic People Mover Station took seven years to complete. "We finished the train tube well ahead of finishing the project," Scaglione reports. But the work didn't end there. CBO Glass' scope included all of the steel and glass that encloses the train system as it passes through the main station, including the: main subway station security mezzanines, People Mover glass enclosure, glass flooring including two large glass bridges, elevator enclosures and glass ceilings that include two sloped glass ceilings at the exit escalators, overhead baggage bridge with a glass ceiling and two large sloped elevations of custom fabricated louvers, an entire stainless steel panel assembly that contains approximately 7,500 stainless steel panels, a four-sided structurally glazed elevator and train tube enclosure, and a custom curtain-wall system.

Among the lead project participants were John McManus, project executive, Turner Construction Co.; Kurt Gavalier, general superintendent, Turner Construction Co.; and David Molino, operations manager, CBO Glass, who was project manager, along with Scaglione, at the time. Skidmore, Owings & Merrill (SOM), New York, was the architect. InKan Ltd., Toronto, fabricated the custom patch fittings that held each of the train tube's 156 emergency egress doors in place. Colgate Industries, Buffalo, provided the steel, and Schott AG in Germany provided the 1 5/16-inch laminated glass with etched top coat that makes up the two glass bridges. The bridges consist of approximately 7,100 square feet of all-glass flooring lit from below that cross over the two trains.