Duncan Aviation

Duncan Aviation

Expanding without interrupting operations

For Duncan Aviation, growth required more than additional space. It required a plan that could expand capacity while keeping daily operations moving.

Based in Lincoln, NE, the project called for multiple buildings to support aircraft storage, maintenance and service functions. Each structure needed to perform independently while contributing to a larger, coordinated system across the site.

Pioneer Construction, a Varco Pruden™ Builder, approached the project with a clear objective: deliver each phase in a way that supports ongoing operations while building toward the full campus vision.

Building in phases, not pieces

The project included eight buildings totaling more than 60,000 square feet of indoor storage space, along with a larger hangar facility and maintenance building. Rather than treating each structure as a standalone effort, the team developed a phased approach that aligned construction with operational priorities.

Initial buildings were completed first to establish immediate capacity. Once those structures were in place, the team advanced to additional facilities, including the Hangar 6 addition.

This sequencing allowed Duncan Aviation to begin using new space while construction continued elsewhere on site. It reduced pressure on existing facilities and created a smoother transition as the full campus came online.

By the time work progressed to the main Hangar 9 building, the team had already established momentum, both in construction and in operational readiness.

Engineering for scale and function

The Hangar 9 building introduced a new level of complexity. Larger in scale and more demanding in execution, it required careful coordination across structural systems, erection sequencing and site logistics.

Delivered in multiple stages, the building’s construction began in April and reached completion by the end of 2023. This phased delivery allowed crews to manage structural assembly efficiently while maintaining control over quality and schedule.

Across the site, building systems were selected to support long-term performance. The SSR™ Roof System provides continuous weathertight protection, reducing maintenance requirements and supporting durability in demanding conditions. Panel Rib™ Wall System panels contribute to structural consistency and a clean exterior appearance while maintaining efficient installation.

Masonry elements were incorporated to enhance the visual character of the buildings, creating a balance between performance and architectural presence.

Inside the maintenance building, three service bays were designed to accommodate a range of vehicles, including large fuel and de-ice trucks. Two of the bays were specifically configured to handle the largest equipment in Duncan Aviation’s fleet, ensuring that the facility could support current operations and future demands.

Coordination that drives results

Projects of this scale depend on more than design and materials. They rely on coordination between teams, across phases and throughout the construction process.

Pioneer Construction worked closely with Varco Pruden to align engineering, fabrication and delivery schedules with the realities of the job site. Structural systems were detailed with constructability in mind, allowing crews to move efficiently from one phase to the next.

This level of alignment reduced delays and allowed each building to come online as planned. It also created consistency across the site, ensuring that each structure met the same performance and quality standards.

While the project presented challenges in scale and sequencing, the outcome reflects a process that stayed focused on execution. Each phase built on the last. Each decision supported the next step forward.

A campus built for continued growth

Today, the completed development provides Duncan Aviation with expanded capacity across storage, maintenance and aircraft servicing. The campus functions as a unified system, allowing operations to scale without disruption.

The phased approach not only supported construction efficiency but also positioned the facility for long-term use. Each building contributes to a broader operational strategy, ensuring that the site can adapt as needs evolve.

Recognized as a 2024 Hall of Fame “Best of Category” winner in the Transportation category, the project reflects what is possible when planning, partnership and execution stay aligned from start to finish.

For Pioneer Construction and Varco Pruden, the project demonstrates a practical approach to complex expansion, one that prioritizes continuity, performance and the ability to build without slowing what matters most.

Because in aviation, timing matters. And the right building solution ensures everything stays on schedule.