Airports are not just built or constructed to exist – they are shaped with vision and crafted to endure. The new terminal building at Tuticorin Airport, developed at a cost of around Rs 4.5 billion, stands as a landmark of design, engineering and sustainability. Spread across 17,340 sq m, it is equipped to handle 1,350 passengers during peak hours and 20 lakh passengers annually, with an expansion capacity up to 1,800 passengers per peak hour and 25 lakh annually. With 100 per cent LED lighting, energy-efficient E&M systems and treated water reuse through an onsite sewage treatment plant (STP), the terminal is targeting a GRIHA-4 sustainability rating. For southern Tamil Nadu, this modern infrastructure promises enhanced air connectivity, tourism, trade and investment – a true milestone.Building through challengesThe project was executed by KEC International under a turnkey design-and-build model. As Nagesh Veeturi, Executive Director - Civil, explains, “The project presented a unique set of engineering and logistic challenges. Expanding passenger capacity required significant structural upgrades, strengthening foundations and columns and installing over 500 mt of pre-engineered building (PEB) frames to create additional floor plates. We also replaced the HVAC system with higher-capacity chillers and upgraded airport and IT systems, which were entirely new domains for KEC.”Delivering such an ambitious scope in a remote location demanded meticulous resource mobilisation. “Logistically, delivering these works in a remote southern location required meticulous planning and resource mobilisation,” he adds. “The project also demanded close coordination for MEP services and multiple approvals from the Airports Authority of India (AAI).” To overcome this, KEC adopted a phased approach. “Our solution was a phased execution strategy, allowing parallel progress across the terminal building, apron, ATC tower and support facilities,” shares Veeturi. “This was backed by intensive 12-month construction, followed by commissioning and handover. Throughout, we maintained strict quality controls and continuous stakeholder engagement, ensuring timely delivery despite the complexity.”A green benchmarkFrom the outset, sustainability was embedded into construction. “The Tuticorin Airport terminal has been designed to achieve a four-star GRIHA [Green Rating for Integrated Habitat Assessment] certification by embedding sustainability into every stage of construction,” continues Veeturi. “Key measures include using energy-efficient materials and systems, installing a solar captive power plant, implementing sewage treatment and rainwater harvesting with recharge for reuse, and applying the ‘Reduce-Reuse-Recycle’ principle in waste management. An advanced energy management system further minimises wastage. All these initiatives were seamlessly integrated into the project plan, ensuring compliance with GRIHA standards without impacting timelines or performance.”Materials with meaningEvery element was carefully chosen to reflect performance standards and regional character. “Material and vendor selection were driven by AAI specifications, stringent performance standards and the project’s design intent,” elaborates Veeturi. “The façade incorporates Chettinad-inspired GFRC elements crafted by a Gurgaon specialist, while the lobby ceiling features wind-resistant Luxalon panels from Hunter Douglas (Chennai). Granite flooring in ‘Athunik Brown’ was sourced from Andhra Pradesh and baffle-type false ceilings in the arrival hall were chosen for a clean, modern finish. Interior artworks and sculptures were prefabricated in Chennai to maintain quality control and landscaping involved replacing silty soil with nutrient-rich red soil for lasting greenery. All vendors were appointed through AAI’s tendering process, ensuring adherence to quality, performance and delivery requirements.”Design visionFrom an architectural standpoint, Ar. Gurpreet S Shah, Principal Architect, Creative Group LLP, says, “Sustainability was a core driver of both design and implementation at Tuticorin Airport, with the new terminal designed to achieve a four-star GRIHA rating. Several integrated strategies were adopted to minimise environmental impact and enhance long-term efficiency. A 230-kld STP treats wastewater for complete reuse in flushing and landscape irrigation. To conserve water, the project also incorporates a robust rainwater harvesting system with wells and storage tanks that recharge the aquifer and stabilise the local water table. Complementing this, 1,500 trees were planted across a green belt to strengthen the ecological footprint.”On the energy front, he adds, “Energy-efficiency was central to the design, with a 300-kw rooftop solar plant generating renewable energy onsite. Material selection was equally sustainability-driven: AAC blocks and fly ash-based PPC were used for masonry and insulation; manufactured sand replaced river sand to conserve natural resources; and waste concrete was recycled into cover blocks. To enhance thermal comfort and reduce HVAC load, Saint-Gobain DGU façade glass was chosen. Additionally, all HVAC insulation materials and refrigerants are CFC/HCFC-free and fire safety systems employ Halon-free extinguishers, underscoring the eco-conscious approach.”The terminal also sought to embody local identity. “The design vision for the Tuticorin Airport terminal was to transcend conventional airport typologies by creating a facility that celebrates regional identity while delivering modern functionality,” explains Shah. “Inspired by the vernacular Chettinad houses, the architecture blends traditional cultural elements with contemporary forms, positioning the terminal as both a gateway of connectivity and a cultural landmark.”Balancing aesthetics with functionality was achieved through a future-ready design approach. The terminal integrates modern amenities such as aerobridges, advanced baggage handling systems and enhanced passenger facilities to elevate the travel experience. To meet growing demand, the runway was extended to handle larger aircraft like the Airbus A-321, boosting regional and national connectivity. These infrastructural upgrades, combined with a design that resonates with local culture, ensure that the terminal is both operationally efficient and contextually rooted.Smart power backboneSustainability also shaped the electrical strategy. “The terminal incorporates 300-kw solar power,” reveals Amit Saraswat, Director - Marketing, Saraswat Engineering Services. “Street lighting is separately powered through solar power, smart LED lighting, energy-efficient motors, transformers and backup power systems with redundancy to reduce energy use and operational costs, effectively lowering the carbon footprint.”Highlighting advanced systems, he adds, “The terminal features resilient power infrastructure, smart grids, automation technologies and automated baggage handling, all aligned with modern safety and performance standards. It uses high-definition CCTV with real-time monitoring and analytics for enhanced security coverage. Modern access-control systems secure restricted zones and track personnel movement. The airport is GRIHA 4 Star-certified, reflecting advanced sustainable design and construction that meets high standards for energy efficiency, water conservation and environmentally responsible materials. This certification demonstrates the airport’s commitment to reducing its environmental impact while providing modern amenities.”From its structural engineering and sustainable materials to its cultural design inspiration and smart power systems, the new Tuticorin Airport terminal sets a benchmark in future-ready regional aviation infrastructure – one that is as thoughtfully crafted as it is meticulously constructed.