DHL Express has announced a significant investment of US$192 million to construct an aircraft maintenance facility at Cincinnati/Northern Kentucky International Airport (CVG). The purpose of this facility is to support the growth of its expanding fleet at its primary U.S. air hub.
The Kentucky Economic Development Finance Authority has given its approval for US$1 million in incentives for the 305,000-ft² maintenance facility. It will encompass dedicated space for aircraft parts storage, three maintenance parking gates and eight new aircraft gates.
The new maintenance centre will be situated adjacent to DHL’s existing cargo operations on 50 additional acres leased from the airport. The facility will accommodate two Boeing 777 wide-body freighters side by side. The company aims to complete the project by the end of 2025.
CVG Airport serves as the central connection point for DHL’s express network to the rest of the world. With a fleet of 60 aircraft, DHL operates 130 daily flights. The facility is also crucial for partner airlines and joint venture Polar Air. Currently, the super-hub spans 194 acres, featuring 67 aircraft parking gates and 6.4 million-ft² of ramp area. Annually, it processes approximately 50 million international shipments destined for the U.S., Canada, Mexico and Latin America.
In recent years, DHL has invested over US$250 million in hub upgrades since 2015, focusing on aircraft handling equipment, auto-sort systems and renovated interior sections. The company also operates hubs in Germany and Hong Kong.
Currently, DHL Express conducts some of its repairs on the tarmac at CVG. However, larger tasks are outsourced to FEAM Aero, which is in the process of constructing a second maintenance hangar. This expansion initiative aims to provide sheltered line maintenance activities for DHL’s fleet of Boeing 737, 767, and 777 aircraft. A combination of in-house and FEAM technicians will be responsible for maintaining the fleet.
