Construction at Duncan Aviation’s new Pratt & Whitney Canada DOF (Designated Overhaul Facility) for PW300 and PW500 turbofan engines is rapidly progressing, with the 36,000-square-foot expansion reaching significant internal development stages. Designed by Tectonic Management Group and constructed by Hausmann Construction, the DOF is now fully enclosed, with interior work in full swing.
The expansive new space features 12 dedicated engine maintenance bays, a new parts inventory warehouse, and significantly expanded backshops. The expansion includes new offices, conference rooms, a breakroom, modern bathrooms, locker rooms, and additional workstations available to customers.
Demonstrating our commitment to safety and efficiency, we are installing 16 one- and two-ton overhead cranes throughout the new shop. These enhance safe, precise handling of large engine components, improving productivity and technician safety.
Significant upgrades are also underway for the building’s utility infrastructure, including a larger evaporator drain pit for chemical recycling and a substantially upgraded fuel farm. Its 12,000-gallon tank supplies two 3,000-gallon tanks, ensuring continuous test cell operation during refueling—a significant efficiency improvement.
In-house engine capabilities are expanding with advanced tooling: an Aerospect Measurement and Stack Prediction System for compressor stack measurements, a coordinate measuring machine for precise dimensional inspections, dedicated bearing inspection rooms, a plasma spray booth for internal part repairs, and sophisticated vertical and horizontal grinders.
All existing in-house engine backshops are expanding, upgrading machinery, and are centrally located among authorized engine OEM operations. These include clean rooms, media blasting equipment, shot peening equipment, a paint booth, NDT capabilities, and a balance room, all enhancing maintenance team efficiencies.
The new DOF test cell and control room, designed and installed by Atec, Inc., is scheduled to arrive on-site in September 2025, and will be placed adjacent to Duncan Aviation’s existing test cell. It features Atec’s next-generation small turbofan technology, offering a quieter testing environment with greater airflow and reduced environmental impact. Following pre-assembly, test fitting, and load testing, shakedown runs and commissioning are scheduled for February 2026.
The DOF will move into the new addition in November 2025, with overall project completion targeted for April 2026.