DHL is investing $192 million to expand its maintenance facility at Cincinnati/Northern Kentucky International Airport (CVG) in efforts to accommodate its growing fleet.
The cargo carrier is building a new 305,000 ft.2 facility at the airport on 50 additional leased acres. It will include a LEED-certified, carbon neutral hangar that can accommodate two Boeing 777s simultaneously, space for aircraft component storage, offices, and additional ramp and parking space. DHL says the expansion will also enable weatherproofed line maintenance for its fleet of 737s, 767s and 777s.
According to Mike Parra, CEO of DHL Express Americas, growing customer demand has driven the need to expand its footprint at CVG. “Our Americas hub is one of three DHL global superhubs and completes the backbone of our intercontinental network. We are excited for this new project to meet the needs of our partners and employees with a new carbon neutral, state-of-the-art facility for maintenance operations of our growing fleet,” he says.
As part of its recent overall capacity expansion, DHL purchased 28 new 777-200F freighters between 2018-22, 19 of which are currently in service. The remaining aircraft are scheduled to be delivered between this year and 2025. In April, DHL also ordered nine Mammoth Freighters 777-200LR passenger-to-freighter conversion from aircraft dealer Jetran. The aircraft are expected to be delivered to DHL between 2024-27.
Since 2015, DHL has also invested more than $250 million in hub upgrades at CVG. These include new aircraft handling equipment, autostore systems, and various facility remodels and enhancements.
DHL is not yet sharing details about how much the maintenance facility is expected to increase its capacity at CVG or whether it plans to hire more staff as part of the expansion.
Growing cargo demand at the airport is also driving expansions at other companies. MRO provider FEAM Aero is in the process of building a second $40.2 million hangar. In partnership with Epic Flight Academy, FEAM is also building an aircraft mechanic training school on site to grow local maintenance workforce.
DHL’s expanded maintenance facility is expected to be completed by the end of 2025.
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