KAI is providing mechanical, electrical and plumbing (MEP) engineering services for the new $114 million Maintenance Complex at St. Louis Lambert International Airport (STL).
The 285,000-square-foot complex will replace the existing 135,000-square-foot facility, which dates back to the 1960s and is located in a flood-prone area. Situated on higher ground, the new facility will provide expanded, modernized space to meet the maintenance and sheltering needs of modern airfield equipment. The project will also consolidate critical airfield operations into two modern facilities, including snow removal, vehicle repair, materials warehousing, landscaping and maintenance functions. These operations are currently spread across nine buildings, some of which are more than 50 years old.
The complex consists of two primary buildings. The main operations and support facility will house vehicle maintenance and repair operations, warehouse and storage functions, training and conference space, administrative offices, locker facilities and critical building infrastructure. The building is targeting LEED Silver certification.
A second building, the vehicle storage and maintenance facility, measures approximately 200 feet by 600 feet, roughly the size of two football fields, and will provide enclosed storage for snow removal equipment, deicing vehicles, mowers and other specialized airfield equipment. The building will also include wash bays, service areas and operational support spaces designed to keep airport vehicles and equipment ready for year-round service.
The project design also accommodates a future deicing pad to support winter operations on the site vacated by the existing buildings.
KAI’s engineering team is responsible for the complex’s mechanical, electrical and plumbing systems, supporting a highly specialized environment that includes vehicle maintenance operations, equipment storage, warehouse functions, administrative spaces, wash bays, training facilities and secure air-side operations. The systems are designed to maximize energy efficiency, reliability and long-term operational performance while supporting the main building’s pursuit of LEED Silver certification.
Construction began in October 2025 and is expected to be completed in late 2027. Wright Construction Services serves as the project’s general contractor; Kwame and HR Green, Inc. serve as the Program Manager. Jacobs is the prime designer for STL’s complex, serving as both the architectural firm and the structural engineer on this project.
Once complete, the modernized complex will support the airport’s around-the-clock operations by consolidating functions currently housed in nine aging buildings into two modern facilities, providing expanded indoor space for equipment storage and maintenance while improving response capabilities during inclement weather.
“This facility is far more than a maintenance garage,” said KAI Mechanical Group Leader Peter McDonnell, PE, LEED AP BD+C. “It will serve as the operational hub for many of the airport’s critical support functions, from vehicle maintenance and equipment storage to snow removal and deicing operations. Our engineering team focused on delivering resilient, high-performance systems capable of supporting those mission-critical functions around the clock.”
Funding for the project was made possible through a $20 million grant from the Federal Aviation Administration and a $4.6 million grant under the Airport Infrastructure Grants program through the Bipartisan Infrastructure Law.
“This new facility represents a major step forward in strengthening the airport’s infrastructure,” said STL Airport Director Rhonda Hamm-Niebrugge.
St. Louis Lambert International Airport is the primary commercial airport serving the St. Louis metro area and parts of eastern Missouri and southern Illinois, accommodating approximately 15.6 million passengers annually. The airport is an Enterprise Fund Department of the City of St. Louis and wholly supported by airport user charges. No general fund revenues are used for the operation, administration, promotion or maintenance of airport facilities.