Aircraft Maintenance Complex Relocation & Expansion

Fast-tracked maintenance facilities assist United Airlines with move to Houston’s Bush Airport

This three-year project was fast-tracked to create a multi-facility maintenance complex at the George Bush Intercontinental Airport in Houston, Texas. The new complex allows United Airlines to consolidate its heavy and routine aircraft maintenance by transferring its operations from their inadequate facilities at William P. Hobby Airport to more spacious quarters at Bush Intercontinental Airport.

The buildings support both line maintenance and heavy maintenance of United’s fleet of Boeing aircraft models 737, 757, 777 and 787. This $160 million project includes a new 185,000 SF 2.5-bay line maintenance hangar that encloses three wide-body aircraft, new 17,600 SF GSE building, new 26,430 SF engine build-up building (EBU), the addition of 500,000 SF of aircraft apron including 460 LF of blast fence, two engine run-up pads, new 120,000 SF heavy maintenance support shops building, renovation of existing Hangar E for narrow-body heavy maintenance, renovation of a 125,000 SF existing material / parts storage building, and a new 25,000 SF bulk storage building.

A challenge with this project was when the AHJ changed sites on us in the middle of planning. Our team quickly adjusted and kept this entire project on-track by weekly clients meetings and fast turnarounds for design deliverables.

The facilities include a number of sustainable design features, including high-efficiency HVAC, plumbing and LED lighting fixtures, widespread use of natural lighting, design for a future photovoltaic solar collection system, and the use of native plant species to reduce the need for irrigation. Multiple fire protection and security systems are in place, including a blast deflector capable of withstanding the full power take-off velocities of all commercial aircraft.

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George W. Bush Intercontinental Airport, Houston, TX


United Airlines


1,543,600 SF

Multi-facility maintenance complex
Large hangar will accommodate 3 wide-body aircraft
Design elements for hangar, warehouse & support shops