Lufthansa Technik Heavy Maintenance Facility

Aguadilla, Puerto Rico

Building a five-line overhaul facility in a fledgling aerospace sector.

The requirements of designing and constructing a five-bay aviation maintenance, repair and overhaul (MRO) facility are significant. When you’re building the advanced, 215,000-square-foot facility on a Caribbean island, it creates an entirely different set of considerations. That’s why Lufthansa Technik turned to the aviation and aerospace experts at Haskell.

Haskell’s state-of-the-art facility and systems design streamlined operations.

Haskell provided complete A/E design — including design of a downdraft paint bay mechanical system — and project management for the expansive project at Rafael Hernández International Airport in Aguadilla. The site is strategically positioned within flying distance of all Airbus A320 family aircraft in the Americas. The facility includes four Airbus A320 family maintenance bays; support shops including composite, sanding, paint, MEK, interiors, welding and riveting, sheet metal, heat treatments and a tool crib; and a second-floor administrative center.

The MRO center is prepared to serve the world’s extensive Airbus fleet.

Haskell’s team met the logistical and seasonal challenges and achieved all project target dates so operations began on schedule. The final configuration offers five lines for base and heavy maintenance checks (C-, IL- and D-checks), along with other maintenance work on narrow-body aircraft. Today the facility’s growing workforce of more than 300 employees can service multiple aircraft simultaneously thanks to advanced technology and the facility’s towering 69.5-foot steel frame structure with full overhead crane coverage and hanging tail docks.

  • 215,000 SF heavy maintenance facility
  • Five-bays service A320 family and other narrow body aircrafts
  • 14,281 SF administrative area
  • State-of-the-art technology allows painting and overhaul work to be done in parallel
  • Foundations, footings and slab-on-grade
  • Concrete tilt-wall panels fabrication & erection
Vice President & Division Leader – Aviation & Aerospace Manufacturing

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Haskell's work was of the highest quality that we could ask for from a design-builder. Their commitment to understanding our goals for the project was an asset to project completion. If you want someone who can build your project on-time and on-budget with high quality, Haskell is a good place to begin your search."

Elmar Lutter
Chief Executive Officer, Lufthansa Technik
Exterior of Lufthansa Technik Heavy Maintenance Facility at night. Airplane entering hangar in the back.

Haskell's work was of the highest quality that we could ask for from a design-builder. Their commitment to understanding our goals for the project was an asset to project completion. If you want someone who can build your project on-time and on-budget with high quality, Haskell is a good place to begin your search."

Elmar Lutter
Chief Executive Officer, Lufthansa Technik
Airplane sitting inside Lufthansa Technik Heavy Maintenance Facility.

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