Design Intent to a Fabrication-Ready Panelized Solution

Overview

The Radius Track team worked in collaboration with subcontractors, architect of record AECOM, and general contractor Suffolk Construction. Radius Track developed, engineered, fabricated, and delivered 100,000 lineal feet of cold-formed metal framing solutions for the doubly curved freeform design:

• Exterior façade and roof system including bull nose and integral hidden gutter
• Interior walls, soffits, gate piers, fascia, and ceilings
• Stick framing, panels, and jigging for Terminal E's complex geometry

Problem & Approach

AECOM in collaboration with luis vidal + architects provided an elegant design via concept model defining the desired geometry for a delegated design solution. Each panel was doubly curved, requiring translation of design intent into manufacturable geometry that could be fabricated and installed efficiently.

Three major challenges emerged: speed, coordination, and complexity. Airside and landside operations made logistics challenging, requiring just-in-time delivery sequencing. Radius Track shipped and coordinated 36 full flatbed trucks during the project. The coordination process integrated multiple parties with layers of responsibility.

Radius Track's design model acted as the single source of truth for the installation team. The team developed two separate drawing sets—one each for Century Drywall and Lymo Construction—while maintaining geometric continuity through the project framing model.

“Radius Track is extremely experienced, knowledgeable and solved a lot of problems. They are worth it." – Taking Kong, PM Suffolk Construction

Solution & Results

Radius Track developed solutions to translate AECOM's curved design into single-radius edge geometries manufacturable by Lymo Construction. Solutions for every unique panel enabled automated fabrication and production.

Key technical achievements included:

• Introduced Compass Jig fabrication system to construct complex changing-angle trusses accurately
• Served as bridge between digital design and constructible geometry for AECOM approvals
• Delivered cut-files, simplified panelization, and fabrication data for every panel to Lymo
• Provided value-engineered framing systems and pre-coordinated sub-girt layouts to Century
• Reduced field framing frequency from 16 inches to 10-foot modules, cutting time and labor

The coordinated approach achieved geometric precision across multiple scopes while minimizing site rework. Reusable tools like the Compass Jig improved future project workflows for all parties.

Related Work

Radius Track has completed several additional projects as strategic partners with Century Drywall and Suffolk Construction since Terminal E's completion.

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Team

AOR: AECOM

Design Architect: luis vidal + architects

EOR: Thorton Tomasetti, Simon Design Engineering

CM: Suffolk Construction

Customers: Lymo Construction (metal panel systems) and Century Drywall (interior & sub-framing)

Cold-formed Steel Development & Fabrication: Radius Track Corporation

CFS Engineering: McClure

Awards

Logan Airport’s Terminal E modernization has won at least four major design and construction awards as of late 2025, including international recognition and regional project excellence honors.

Major Awards Earned

• ENR 2024 New England, Project of the Year Finalist and Best Project, Airport Transit: Boston Logan International Airport Terminal E Modernization
• The terminal received the “World’s Most Beautiful Airport” award from the Prix Versailles in 2024, an international accolade it won two years in a row for its design excellence.
• It was named the “2024 Project of the Year” in the Airports and Transportation Centers category by the American Architecture Awards. 
• The Construction Management Association of America (CMAA) New England Chapter gave the Terminal E Modernization its 2024 Mark H. Hasso Project Excellence Award for infrastructure projects over $100 million, praising the design, innovation, and execution.
• “2024 Airport Business,Project of the Year” recognition was also given, reflecting the high standard of project delivery.

Additional Information

Article in The Outsider Magazine, 2025

Article in Architectural Record, 2024

Featured in Conde Nest Traveler Magazine, 2023