O'Hare International Airport's Concourse D Expansion

A major milestone has been reached in the modernization of O’Hare International Airport, as the Chicago Department of Aviation has finalized a Guaranteed Maximum Price agreement for the new Concourse D.

The agreement sets a cost ceiling of $1.455 billion for the 19-gate facility, making it the largest new passenger concourse built at O’Hare in more than 30 years. Even more notable, the project is locked in at least $21 million under the approved budget, providing cost certainty for airline partners and reinforcing confidence in the broader ORDNext program.

So what does it take to deliver a large-scale aviation project with both cost control and construction momentum? Let’s take a closer look.

A Critical Phase of the ORDNext Program

Concourse D represents the first major phase of ORDNext, the City of Chicago’s $8.78 billion airport modernization initiative.

The program is designed to:

• Increase overall gate capacity
• Modernize passenger experience and amenities
• Improve connectivity between terminals
• Replace Terminal 2 with a new Global Terminal
• Strengthen O’Hare’s position as a global aviation hub

City of Chicago News reports that this new concourse is not just an expansion. It is a foundational component of a long-term transformation strategy.

What’s a reliable method to manage a project of this scale? You establish cost certainty early while maintaining flexibility during design and construction.

Guaranteed Maximum Price and Delivery Model

The Guaranteed Maximum Price agreement was reached with the lead contractor team, AECOM Hunt, Clayco, and Bowa Construction.

This delivery structure uses the Construction Manager at Risk model, which allows contractors to be involved early in the design phase.

Key benefits of this approach include:

• Early identification of constructability issues
• Optimized sequencing and scheduling
• Value engineering before final pricing
• Reduced risk of cost overruns

By the time the GMP is finalized, much of the uncertainty has already been addressed.

This is how large infrastructure projects maintain both schedule and budget discipline.

Design and Architectural Features

The new Concourse D has been designed by Skidmore, Owings & Merrill in collaboration with Ross Barney Architects, Juan Gabriel Moreno Architects, and Arup.

The design draws inspiration from O’Hare’s original name, Orchard Field, through a series of signature architectural elements.

Key features include:

• Tree-like structural columns branching outward
• A long-span roof extending approximately 150 feet
• Open and flexible interior layouts for passenger movement
• Adaptable gate configurations for various aircraft sizes

From a construction perspective, these elements introduce complexity in structural engineering and sequencing, particularly with long-span roof systems and custom column geometry.

Construction Progress and Upcoming Milestones

With the GMP agreement in place, the project is entering a more visible phase of construction.

Key upcoming milestones include:

• Installation of a tower crane
• Start of structural steel work for the Midfield Cooling Plant
• Beginning of Concourse D steel erection
• Continued foundation and tunnel work
• Advancement of building systems and enclosure

The Midfield Cooling Plant is a critical support facility that will provide chilled water and air conditioning to Concourse D and future expansions across the airport campus.

Steel and enclosure work are expected to continue through the fall, marking a significant shift from early site work to vertical construction.

Construction Trades Involved

Aviation infrastructure projects of this scale require coordination across a wide range of specialized trades.

Key trades include:

• Sitework and Heavy Civil Contractors
• Deep Foundation and Piling Specialists
• Structural Steel Fabricators and Erectors
• Crane and Heavy Equipment Operators
• Mechanical HVAC Contractors
• Plumbing and Piping Contractors
• Electrical and Power Distribution Teams
• Fire Protection and Life Safety System Installers
• Building Envelope and Curtain Wall Specialists
• Roofing Contractors
• Interior Buildout and Finishing Trades
• Baggage Handling System Installers
• Airport Systems and Technology Integrators

Each trade must work within strict sequencing requirements to maintain safety, efficiency, and operational continuity at an active airport.

Funding Model and Financial Structure

Unlike many large infrastructure projects, Concourse D and the broader ORDNext program are funded entirely through airport-generated revenue.

Funding sources include:

• Airline rates and charges
• Landing fees
• Passenger-related airport revenues

This model eliminates reliance on state or local taxpayer funding while allowing the airport to reinvest directly into its infrastructure.

For developers and contractors, this creates a more predictable funding environment tied to airport operations.

Economic Impact and Industry Opportunities

Beyond the physical infrastructure, the project is expected to generate significant opportunities across the construction industry.

These include:

• Prime contracting opportunities
• Subcontracting packages across multiple trades
• Supplier and material procurement opportunities
• Participation from WBE and MBE firms
• Workforce development and mentorship programs

Large-scale aviation projects like this often serve as long-term pipelines for regional contractors and suppliers.

Looking Ahead to Completion

Construction on Concourse D is expected to continue through 2028, with the facility targeted for completion in late 2028.

As work progresses, the focus will remain on:

• Maintaining schedule discipline
• Coordinating complex trade sequencing
• Managing costs within the GMP framework
• Delivering high-quality construction standards

The project represents one of the most significant infrastructure investments in Chicago in decades.

And as steel begins to rise and the structure takes shape, the vision of a modernized O’Hare will move from planning into reality.

For construction professionals, this is exactly the kind of project that defines the next generation of large-scale infrastructure delivery.