Fast-Tracking United Airline’s Flight Training Future
Turner provided Design-Build services for Building H, a state-of-the-art, five-story, 155,700 sq. ft. flight training facility located at United Airlines’ Flight Training Center (FTC) campus near the former Stapleton Airport in Denver. Executed under a Design-Build delivery model, Turner served as Construction Manager, guiding the project from planning through substantial completion on an accelerated schedule.
The new facility supports United’s expanding pilot training needs—particularly for certification on the 737 Max and 70 Airbus A321neo aircraft—and includes 12 full flight simulator (FFS) bays, six fixed training devices (FTDs), as well as office and training room space. Building H was designed to accommodate both current and future Good Manufacturing Practice (cGMP/fGMP) standards, further enhancing the functionality and future-readiness of United’s training operations.
United Flight Training Center Building H
Challenge
United Airlines needed to expand its pilot training capacity to meet rapid fleet growth, particularly with the addition of 737 Max and Airbus A321neo aircraft. The company required a new training facility that could deliver two full-flight simulator bays on an aggressive 16-month schedule, aligned with aircraft deliveries. This work had to be completed while building on an active, 24/7 training campus.
The project faced multiple challenges: a volatile postpandemic construction market, severe weather events, and an evolving scope that shifted several times before being finalized. United’s mandate remained clear: the first two simulator bays had to be delivered on time, without disruption to training operations or overruns in budget, while ensuring the new building matched the campus aesthetic with a brick-clad exterior.
Solution
Turner and BRPH delivered the project through a DesignBuild partnership built on collaboration, transparency, and schedule certainty. The guiding mantra—“Two Bays in May”—kept the entire team aligned on the critical milestone of early simulator delivery.
The Design-Build approach allowed for rapid decisionmaking, continuous stakeholder engagement, and integrated design and construction planning. Early design-thinking workshops, phased permitting, and progressive scheduling ensured the project remained adaptable to shifting scope. The strategy centered on building a fully functional, self-contained “building within a building,” complete with utilities, egress, and life-safety systems, to enable turnover of two simulator bays months before full project completion.
The project team leaned into challenges beyond contractual obligations—such as adjusting fire alarm reporting methods and ensuring critical utilities were operational —to allow simulator certification without delay.
Prefabricated thin-brick exterior panels accelerated construction while maintaining the required aesthetic, reducing installation time, and increasing onsite safety of the construction staff.
Delivering the project on an active campus also required precise coordination. The team scheduled tie-ins offhours, established a secure and separated construction zone, and maintained a clean, organized site through Lean and 5S practices. A culture of trust and transparency allowed quick resolution of issues, while generous budget holds under the Guaranteed Maximum Price contract enabled prudent risk-taking without jeopardizing cost.
Even severe setbacks, such as a record-breaking rain event that threatened to delay simulator turnover, were overcome through relentless commitment. The project team worked around the clock to protect the facility, demonstrating the collaborative, all-hands mindset that defined the job.
Results
The United Airlines Flight Training Center project met or exceeded every critical goal:
ON-TIME DELIVERY OF TWO SIMULATOR BAYS IN MAY 2023: Enabling pilot training to begin immediately.
COMPLETION OF BUILDING H IN FEBRUARY 2024: A 155,700 sq. ft. facility housing 12 full-flight simulators, 12 fixed training devices, offices, classrooms, and a pedestrian bridge.
ON BUDGET: Supported by proactive scope management and the flexibility of a Guaranteed Maximum Price contract.
PERFORMANCE & SUSTAINABILITY: LEED Silver certification achieved through energy-efficient systems, a robust building management system, and a rooftop photovoltaic array.
COMMUNITY IMPACT: Over 20% of subcontracted work was awarded to underutilized local businesses.
The project became a model of proactive risk management, design-build collaboration, and lean execution. By delivering early simulator capacity, adapting to evolving scope, and ensuring uninterrupted campus operations, Turner established a new benchmark for highperformance aviation training facilities. United recognized the effort as one of the most seamless and successful projects in its history.
Awards
GENERAL CONSTRUCTION DESIGN-BUILDER VERTICAL, DBIA
April 2025, Rocky Mountain Region
BEST OVERALL PROJECT, DBIA April 2025, Rocky Mountain Region
BEST AIRPORT/TRANSIT PROJECT, ENR December 2024, Mountain States Regional Best Project
NATIONAL AWARD OF MERIT, AVIATION, DBIA, 2025
9 MONTHS
FROM START OF CONSTRUCTION TO SUBSTANTIAL COMPLETION OF THE ENCLOSURE
