DHL’s express mail service DHL Express has revealed plans for a $192m aircraft maintenance facility to be built at its primary US superhub at Cincinnati/Northern Kentucky International Airport (CVG). 

The 305,000ft² facility will include eight new aircraft gates and three maintenance parking gates, housing for two Boeing 777 widebody freighters, new offices and aircraft components storage. It will be adjacent to the company’s existing cargo operations at the airport. 

DHL Express Americas CEO Mike Parra said: “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.” 

Development of the LEED-certified, carbon-neutral maintenance hangar set to open at the end of 2025, will be supported by $1m of incentives announced by the Kentucky Economic Development Finance Authority, which has supported the company’s developments since 2009. 

It will allow for the company’s line maintenance activities at the airport to be weatherproofed and the facility will be able to accommodate maintenance for DHL’s fleet of Boeing 737s, 767s and 777s. 

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CVG CEO Candace McGraw said: “DHL’s Global Superhub is an integral part of our regional and state economy. 

“Its success is contingent on having the facilities and workforce able to serve the global air cargo industry and this development aligns with our vision to expand aircraft maintenance and support services on campus.” 

The DHL superhub at CVG currently consists of 194 acres with 67 aircraft parking gates supporting the company’s US network that includes 130 daily flights from 60 aircraft, including 19 new Boeing 777-200F freighters purchased between 2018 and 2022, with 9 more to come. 

The CVG site is one of three DHL superhubs along with one in Hong Kong and another in Germany. 

DHL has invested more than $250m in hub upgrades since 2015 as it seeks to modernise its operations, including an order for nine Mammoth-converted Boeing 777-200LR freighters, which will be delivered between 2024 and 2027. 

DHL Express has also invested in the use of sustainable aviation fuel for some of its flights, including in Italy where it became the first express air courier to use the fuel.