Airline maintenance infrastructure is becoming increasingly important as carriers expand their fleets and heavy maintenance requirements. United Airlines is developing a new complex at Orlando International Airport to increase capacity for maintenance, repair and overhaul operations, with Burns & McDonnell serving as the design-builder.
The project covers more than 300,000 square feet and is intended to support inspections, repairs and aircraft upgrades. United selected progressive design-build for the development, bringing planning, engineering, procurement and construction under an integrated delivery team.
The approach allows construction activities to proceed before all design drawings are finalised. Continued coordination between United and Burns & McDonnell also provides flexibility to address site conditions and make adjustments during project delivery.
During construction planning, the team encountered softer-than-expected soil that could have affected deep foundation requirements. Additional geotechnical investigations and consultations helped identify an alternative solution, according to project details disclosed by Burns & McDonnell.
The new complex is designed to improve operational efficiency and workplace safety. Mezzanines will help manage the movement of parts and materials between aircraft, warehouse areas and maintenance shops while reducing potential conflicts between personnel and equipment.
The development also addresses the limitations of United’s existing maintenance facilities at the airport. More than 1,000 employees work across three existing buildings dating to the 1950s. The project will incorporate a renovated hangar into the new complex, while another hangar located about a mile away is scheduled for demolition.
The facility will include updated work areas, offices, locker rooms and other employee spaces to support maintenance operations.
United’s use of progressive design-build in Orlando could inform its approach to future aviation infrastructure projects. The airline is considering the delivery method for other potential developments, including terminals and flight kitchens.
For airport owners and construction teams, the project illustrates how early collaboration between designers and builders can help address changing site conditions while maintaining attention to schedule and cost objectives. The integrated approach also provides a framework for coordinating complex aviation facilities that must support specialised equipment, aircraft servicing and material handling.
Source: Burns & McDonnell.
