Project

MRO Hangar Complex

We are the integrated design-builder for a maintenance repair overhaul (MRO) hangar complex for United Airlines at Orlando International Airport (MCO). The project is part of United Airlines’ program to support operational excellence and innovation in aviation. Construction began in early 2025 and is phased to minimize disruption to existing facilities.

The 354,400-square-foot MRO complex will feature a maintenance hangar accommodating six narrow-body aircraft or one wide-body and three narrow-body aircraft concurrently, significantly expanding United’s maintenance capabilities. The development will also include a new warehouse, shops, administrative offices and ample employee parking. Additionally, one existing hangar will be renovated and another demolished, creating opportunities for future airport projects.

The new complex replaces the 1950s-era South Hangar with a larger, more versatile facility adjacent to the current North Hangar, which will remain operational. It centralizes maintenance operations, reducing the distance between hangars from 1 mile to a few yards and consolidates the existing warehouse into the new hangar complex.

United’s maintenance facilities at MCO support more than 1,000 local employees. The new campus is set to increase operational efficiency and add long-term value to both the airport and the region. This project represents a significant investment in the airline’s infrastructure, supporting enhanced maintenance capabilities and contributing to economic growth in the region.

Client

United Airlines

Location

Orlando, Florida

Region

Southeast

Services

Aviation

Hangars

Construction

Industries

Aviation

Construction

Truss Lift

image of construction site lift of large truss structure by multiple cranes
image of construction site lift of large truss structure by multiple cranes
image of construction site lift of large truss structure by multiple cranes
image of construction site lift of large truss structure by multiple cranes
image of construction site lift of large truss structure by multiple cranes
image of construction site lift of large truss structure by multiple cranes
image of construction site lift of large truss structure by multiple cranes
image of construction site lift of large truss structure by multiple cranes
Sitework: Reconstructing Pavements

The project involves reconstructing portions of existing concrete pavement apron and restriping the aircraft parking positions to expand the taxilane for airside wide-body operations. Landside, a new vehicle parking area with about 600 spaces will be built. The project will also provide new utility services, such as a fire protection loop, domestic water, sewer and special waste handling areas for aircraft gear washing.

A loading dock will be built with a separate truck access to prevent delivery trucks from crossing parking areas. A new Security Identification Display Area (SIDA) fence will divide the landside parking and circulation areas from the airfield apron with two SIDA gates for airside access. The project will be phased to minimize disruption to existing facilities.

Truss lift by multiple construction cranes