Duncan Aviation celebrated on August 26th the groundbreaking of its new Pratt & Whitney Canada DOF (Designated Overhaul Facility) in Lincoln, Nebraska. The new facility will focus on the overhaul and maintenance of PW300 and PW500 series engines. Pratt & Whitney is an RTX (NYSE: RTX) business.
The ceremony marked a significant milestone as representatives from Pratt & Whitney Canada, Hausmann Construction, Tectonic Management Group, and Duncan Aviation gathered to commemorate the occasion.
Todd Duncan, Chairman of Duncan Aviation, highlighted the long-standing relationship between the two companies, stating, “This groundbreaking symbolizes a trusted commitment between two great companies that dates back decades. It is the result of years of effort through strategic agreements and mutual trust and holds immense significance.”
Duncan believes this agreement with Pratt & Whitney Canada will be one of the most impactful for Duncan Aviation’s future, opening up new opportunities and elevating the company’s service offerings. Although primarily involving engine authorization, its influence will extend across nearly every department at Duncan Aviation. With the completion of the new DOF set for 2026, departments such as airframe maintenance, paint, avionics, completions, and component services are anticipated to see increased demand from operators using Pratt & Whitney Canada engines who require comprehensive MRO services.
Construction Underway
The new 36,000-square-foot facility, designed by Tectonic Management Group and constructed by Hausmann Construction, will include 12 engine maintenance bays, a new parts inventory warehouse, and expanded backshops.
Duncan Aviation has significantly invested in safety enhancements, advanced machinery, and team member training and growth. Safety measures include installing an overhead crane system to improve productivity and safety, enabling easy lifting and precise placement of engine components during assembly and disassembly. A floor-mounted rotating jib crane with a 500-pound capacity facilitates comprehensive, 360-degree engine inspections.
The new DOF test cell and control room, designed and installed by Atec, Inc., based in Houston, Texas, will be adjacent to Duncan Aviation’s existing test cell and will serve PW300 and PW500 engines and feature Atec’s next-generation small turbofan test cell technology, offering a quieter testing environment with greater airflow and less environmental impact. The cell will handle the newest class of business jet and small regional jet engines up to 20,000 lbs. of thrust. Enhancements include a larger fuel farm, start air capability, and generator loading.
In-house capabilities will expand with additional tooling and equipment. These include a coordinate measuring machine for dimensional inspections, a bearing inspection room, vertical and horizontal balancers, and an Aerospect Measurement and Stack Prediction System for compressor stack measurements and vertical engine alignments. The facility will also house a vertical grinding machine for shroud segment grinding in the hot section and a thermal spray booth for internal parts repairs, resulting in significant time savings for customers.
In-house engine capabilities such as a clean room, media blasting machines, shot peen equipment, a paint booth, NDT capabilities, and a balance room are improving, expanding, and centrally located to facilitate maintenance team efficiencies between all OEM authorized operations.
Labor & Training
Duncan Aviation’s P&W maintenance team will expand to six dedicated engine technicians in anticipation of increased service demands. The company projects needing 50 dedicated P&W technicians within 10 years. Duncan Aviation also plans to extend its expertise by training and equipping additional teams at its MRO locations in Provo, Utah, and Battle Creek, Michigan, as well as AOG Rapid Response Teams to conduct hot section inspections on PW500 engines in the field.
Scott Stoki, the Manager of Pratt & Whitney Engine Overhaul Services in Lincoln, believes Duncan Aviation’s engine program isn’t finished growing. “This expansion is an opportunity not only to meet our immediate needs but to prepare for future opportunities. We make every expansion and equipment purchase decision to ensure we are in an excellent position to seamlessly transition into servicing larger and higher-thrust engine platforms in the future.”
The expansion of turbine engine overhaul services underscores Duncan Aviation’s commitment to Pratt & Whitney, their engines, and mutual customers. They are ready to deliver a product that meets the high-quality standards that P&WC demands for its DOFs.