San Francisco International Airport’s decision to renovate its aging Superbay Hangar highlights the need to modernize critical aviation infrastructure without disrupting active airline operations. The approximately $132 million project will require phased construction, extensive stakeholder coordination and progressive design-build collaboration while aircraft maintenance continues inside the facility.
Originally constructed in 1969, the SFO Superbay is one of only two remaining facilities of its type in the United States. The large-scale hangar can accommodate up to four wide-body aircraft simultaneously, with United Airlines operating on the north side and American Airlines on the south side.
The renovation will address multiple components of the facility, including the roof and building envelope, structural and building systems, fire and life-safety infrastructure, aircraft doors, elevators and accessibility improvements. Photovoltaic systems also are planned as part of the modernization.
Electrical infrastructure upgrades will increase the facility’s power capacity and support its long-term operational requirements.
Keeping the Superbay active throughout construction will require work to be coordinated around aircraft maintenance and movement. The approach will allow airline operations to continue while construction teams complete major improvements to the facility.
The W.E. O’Neil-Nibbi Joint Venture combines W.E. O’Neil Construction’s aviation and aircraft hangar experience with Nibbi’s extensive history at SFO and experience with progressive design-build delivery.
The project will be delivered with Project Delivery Partner HCI/InnoActive Joint Venture. The broader design and technical team includes FSB Architects + Engineers, Paulett Taggart Architects, Buehler Engineering, Ryan Joyce Structural Design, AEI Consultants, LEAN, ASSA ABLOY and Stok.
Progressive design-build will allow the airport, airlines, design-build team and trade partners to coordinate project requirements earlier in the process. Key considerations will include safety, constructability, phasing, cost, schedule and continued hangar operations.
The project team also brings direct knowledge of the facility and airport infrastructure. Ryan Joyce Structural Design has previously performed structural work at the Superbay, while LEAN contributes experience with SFO’s electrical infrastructure and power distribution network.
Programming is anticipated to begin in fall 2026, with final completion targeted for summer 2029.
The Superbay renovation demonstrates the construction challenges associated with upgrading aviation facilities that cannot simply be taken offline. For contractors, the project underscores the importance of phased work planning, operational coordination, airport safety requirements and early collaboration among owners, airlines, designers and specialty trade partners.
For airport owners, progressive design-build can provide an opportunity to resolve constructability and operational issues earlier while coordinating modernization work around existing aviation activity. The project also illustrates how investments in aviation maintenance infrastructure can support reliable airport operations.
Source: W.E. O'Neil Construction.
