Structural Steel Inspection for Dallas Fort Worth Airport

Dallas Fort Worth International Airport (DFW) had a large-scale, complex modular structural steel construction project at Terminal F. When AXE Energy Services was brought onto the project, the schedule was already behind, and the fabricator was at risk of losing the contract. The core issue was that the previous inspection provider lacked a practical understanding of the fabrication process and the complexity of the modular build. Their inspection methods were not integrated into the workflow, creating documentation gaps, communication barriers, and constant delays that hindered production.

The project required a quality partner that could be proactive in ensuring that the 3,200 tons of steel met stringent AISC D1.1 structural steel non-destructive testing (NDT) inspection requirements.

Unlike typical inspection assignments, this project required us not only to verify quality but also to integrate inspection practices directly into the fabrication workflow. AXE Energy Services approached the inspection requirement with the mindset of a fabricator. By leveraging our deep, practical background in structural steel construction and AWS D1.1 codes, we transformed the quality control process into a collaborative partnership.

Our team implemented a proactive, integrated solution:

• Integrated quality control. Instead of waiting for post-fabrication punch lists, we integrated our certified inspectors directly into the fabrication workflow.
• Real-time feedback & coordination. We held daily coordination meetings and provided real-time feedback to the fabricator to address potential non-conformances immediately, rather than letting issues compound. We also coordinated closely with multiple trades and contractors in this modular environment, resolving prior miscommunication and scheduling conflicts.
• Streamlined processes. We quickly reviewed existing documentation, identified bottlenecks, and redesigned inspection steps to match the actual build sequence of the modular steel, eliminating confusion and rework.
• Advanced non-destructive examination (NDE). Our team utilized advanced NDE techniques, including Ultrasonic Testing (UT), Magnetic Particle Testing (MT), and Visual Testing (VT), using equipment like the Epoch 450 to confirm weld integrity without slowing down production.

By transitioning from a traditional oversight model to an embedded, solutions-oriented partnership, AXE Energy Services delivered exceptional results that saved the project:

• Schedule rescued. We brought the project back on track, with successful completion within the required six-month delivery timeframe.
• High quality. We guaranteed zero non-conformances, meaning all 3,200 tons of structural steel met stringent 1/16​” tolerances and AISC D1.1 standards.
• Fabricator success. By providing outstanding partnership and work, we helped the fabricator avert losing their contract and enabled them to deliver the complex modular build on time and within budget.

DFW commended us for our outstanding work partnering with the fabricator to deliver the project. We demonstrated that superior structural steel inspection is not merely about finding faults, but about understanding the fabrication process well enough to prevent them.

If your structural steel project demands tight tolerances, complex coordination, and a quality partner who understands fabrication from the ground up, reach out to AXE Energy Services. Contact us to discuss how our fabrication and inspection expertise can ensure your next build is delivered on time, within budget, and with zero non-conformances.