
Austin-Bergstrom International Airport Expansion
The Austin-Bergstrom International Airport (AUS) East Expansion of the Barbara Jordan Terminal added nine gates to accommodate increasing passenger traffic and support the future growth of air service to the rapidly expanding metropolitan area of Austin, Texas.
CAST CONNEX designed and supplied custom steel castings for the terminals long-span Architecturally Exposed Structural Steel (AESS) trussed roof, as well as Universal Pin Connectors (UPC) supplied for use in tension struts on the added exterior observation deck.
Owner: City of Austin
Architects: Gensler
Structural Engineers: TYLin
General Contractor: Hensel Phelps
Steel Fabricator: W&W/AFCO Steel

The 175,000 square-foot (16,260 square-meter) expansion provides concessions, outbound baggage handling, airline offices, and additional passenger amenities, including a large outdoor observation deck.
Long-span, AESS roof trusses span the width of the concourse. CAST CONNEX designed and supplied custom castings to support the roof trusses. These custom castings create pinned connections between the columns and long span roof trusses. The use of custom castings simplified on-site construction by eliminating the need for complex field welding. The flexibility provided by custom castings also helped achieve the slender geometry of the pins, contributing to the design vision of an airy environment with open sightlines throughout the concourse.
CAST CONNEX Universal Pin Connectors (UPC) were also used at the bases of the roof truss tension struts exposed on the terminal’s open-air observation deck. This pre-engineered cast steel solution enhanced the structure's aesthetic appeal while simplifying the fabrication of the sloped hollow structural sections (HSS). The result is a clean, architecturally expressive design that helps showcase Austin’s appreciation for outdoor living to arriving and departing passengers.
.webp)





