MRO & Manufacturing
Caerdav Doubles Aircraft Maintenance Capacity in UK Expansion
Caerdav expands St Athan facility, doubling MRO capacity focused on Boeing 737 and Airbus A320 aircraft amid rising global aviation demand.
In the world of aviation, the work on the ground is just as critical as the performance in the air. The Maintenance, Repair, and Overhaul (MRO) sector is the backbone of the industry, ensuring the global fleet remains safe, airworthy, and efficient. Within this demanding landscape, South Wales-based Caerdav has just made a significant strategic move, completing a major expansion project that effectively doubles its aircraft maintenance capacity. This development isn’t just a win for the company; it’s a calculated response to a global surge in demand for MRO services, positioning Caerdav as a more formidable player in the European market.
The timing of this expansion is pivotal. The aviation industry is experiencing a robust recovery, leading to an expanding global aircraft fleet and an increasing number of older aircraft requiring more intensive maintenance schedules. Airlines and leasing companies are in constant need of reliable partners to handle everything from routine checks to complex overhauls. Caerdav’s decision to increase its capabilities, particularly for the workhorse narrowbody jets, aligns perfectly with these powerful market currents. By investing in infrastructure and enhancing its service offerings, the company is preparing not just for today’s demand, but for the projected growth of the coming decade.
This move solidifies the St. Athan facility’s role as a key hub in the UK’s aviation support network. For South Wales, it signals economic growth, bringing more skilled jobs and opportunities to the region. As we break down the specifics of this expansion and the market context it fits into, it becomes clear that this is more than just adding another service line; it’s about building a more resilient, efficient, and vertically integrated operation ready to meet the future of aviation head-on.
The core of Caerdav’s project is the opening of a fourth maintenance line at its “Twin Peaks” hangar in St. Athan. This addition is the culmination of an 18-month strategy that has successfully doubled the company’s operational capacity. Where the facility could previously service two aircraft, it can now handle four simultaneously. This leap in throughput is crucial for attracting and retaining contracts with major airlines and aircraft leasing companies, who prioritize speed and availability in their MRO partners.
The expansion is specifically tailored to the most common aircraft in the skies: the Boeing 737 and Airbus A320 families. These narrowbody jets are the backbone of short and medium-haul travel globally, and their high utilization rates mean they require frequent and thorough maintenance. By focusing its enhanced capacity on these aircraft types, Caerdav is directly targeting the largest and most consistent segment of the MRO market. This specialization allows for greater expertise, more efficient workflows, and a stronger competitive edge.
However, the project involved far more than just clearing floor space. It was a comprehensive remodelling of the hangar to improve overall efficiency and broaden the scope of work that can be completed on-site. This strategic enhancement of the facility’s infrastructure is what truly elevates the impact of the fourth line, transforming it from a simple capacity increase into a fundamental upgrade of the company’s service proposition.
A key element of the expansion was the integration of new workshops and “back shop” capabilities. This move toward vertical integration is a game-changer for operational efficiency. By bringing more services in-house, Caerdav can exert greater control over project timelines, reduce reliance on external suppliers, and ultimately shorten aircraft turnaround times, a critical metric for its customers. The less time an aircraft spends in the hangar, the more time it spends generating revenue.
The new on-site services are extensive and address common maintenance needs. The facility now includes dedicated workshops for composite repairs, a crucial capability given the increasing use of lightweight composite materials in modern aircraft. Furthermore, the addition of non-destructive testing (NDT) and specialized paint services means that more complex repair and restoration work can be completed under one roof. This comprehensive, self-contained service offering makes Caerdav a more attractive, one-stop-shop for its clients. “With the global demand for aircraft maintenance continuing to increase, opening a fourth line was the next phase of our detailed growth strategy. We are delighted to be in a position to bring additional jobs and opportunities to South Wales.”
– Chris Coleman, Managing Director at Caerdav
This investment in in-house capabilities reflects a broader industry trend toward efficiency and streamlined operations. For airlines and lessors managing end-of-lease transitions or heavy maintenance checks, the ability to have all necessary work done at a single facility is a significant logistical and financial advantage. Caerdav’s expansion directly addresses this need, positioning it to handle more complex, multi-faceted maintenance projects from start to finish.
Caerdav’s expansion is not happening in a vacuum. It is a direct and timely response to the powerful growth trajectory of the global aircraft MRO market. Industry forecasts paint a clear picture of a sector in ascent, with its value projected to exceed $100 billion in 2025 and continue on a strong growth path over the next decade. One report anticipates the market will reach $105.29 billion by 2029, expanding at a compound annual growth rate (CAGR) of 6.4%.
This growth is fueled by a confluence of factors. The post-pandemic rebound in air travel has reactivated fleets worldwide, while the overall number of aircraft in service continues to grow. Simultaneously, many existing aircraft are aging, which necessitates more frequent and intensive maintenance checks to ensure they remain compliant with stringent safety standards. These dynamics create a sustained, high-demand environment for MRO providers, making capacity and efficiency the keys to success.
Furthermore, the industry is seeing a trend toward outsourcing MRO services. Airlines are increasingly focusing on their core operations of flying passengers and cargo, preferring to partner with specialized, independent MROs like Caerdav. This allows them to leverage expert knowledge and state-of-the-art facilities without the immense capital investment required to maintain such capabilities in-house. Caerdav’s status as a fully independent provider is a core strength in this market, allowing it to serve a diverse customer base without conflict of interest.
A crucial aspect of Caerdav’s strategy is its sharp focus on the narrowbody aircraft market. The Airbus A320 and Boeing 737 families are not just popular; they are the dominant force in the global fleet. Projections indicate that narrowbodies will increase their share of the world’s aircraft from 62% to 68% by 2035. This segment’s dominance is a direct driver of MRO demand, making specialization a highly effective strategy.
By doubling its capacity for these specific aircraft, Caerdav is positioning itself to capture a larger share of this expanding and lucrative market segment. The company’s expertise and tailored facilities allow it to perform maintenance on these aircraft with high efficiency. This focus is a clear advantage when competing for contracts from the numerous airlines and leasing companies that operate these fleets.
“Having signed agreements with a range of new customers, from airlines to major leasing companies, we are now in a position to fill our hangars throughout the year – which is the target for every aircraft MRO.”
– Chris Coleman, Managing Director at Caerdav This alignment with market-analysis trends demonstrates a forward-thinking approach. As the aviation industry continues to evolve, with a focus on data-driven maintenance and operational efficiency, MROs that are specialized, agile, and well-equipped will be the ones that thrive. Caerdav’s recent moves place it firmly in that category.
Caerdav’s completion of its fourth maintenance line is a landmark achievement that transcends a simple capacity increase. It represents a strategic enhancement of its entire operational model, combining increased throughput with a deeper well of in-house capabilities. By doubling down on the world’s most prevalent aircraft families and vertically integrating key services like composite repair and painting, the company has made itself a more efficient, reliable, and attractive partner in the fiercely competitive MRO landscape. This move is a testament to a clear-eyed growth strategy that is perfectly synchronized with the demands of the global aviation market.
Looking ahead, the future for Caerdav and the South Wales aviation sector appears exceptionally bright. The expansion is set to create more skilled jobs and reinforce the region’s reputation as a center of excellence for aerospace engineering. The company’s commitment to its apprenticeship program further signals a long-term investment in building a sustainable talent pipeline. As the global fleet continues to grow and age, Caerdav is now better positioned than ever to secure its place as a leader in the aircraft maintenance industry, ready to fill its hangars and help keep the world flying safely.
Question: What was the main goal of Caerdav’s recent expansion project? Question: What types of aircraft does Caerdav specialize in? Question: What new services can Caerdav now offer on-site? Question: Why is this expansion significant for the aviation industry?
Caerdav Doubles Down: A Strategic Expansion in a Surging Aircraft MRO Market
A Calculated Growth: Inside the ‘Twin Peaks’ Facility Upgrade
Enhanced In-House Capabilities
Riding the Wave: Aligning with a Booming Global MRO Market
The Narrowbody Advantage
Conclusion: A Bright Future Forged in Steel and Strategy
FAQ
Answer: The primary goal was to double the company’s aircraft maintenance capacity by opening a fourth maintenance line, allowing it to service four aircraft at once instead of two.
Answer: Caerdav specializes in the maintenance, repair, and overhaul of the Boeing 737 and Airbus A320 aircraft families, which are the most common narrowbody jets in the global fleet.
Answer: The expansion included the addition of new workshops, allowing Caerdav to offer more in-house services such as composite repairs, non-destructive testing (NDT), and specialized repair and restoration paint services.
Answer: It comes at a time of high global demand for MRO services. By increasing capacity and efficiency for the most common aircraft, Caerdav is helping to support the needs of a growing and aging global fleet, which is crucial for maintaining airline operational readiness and safety.
Sources
Photo Credit: Caerdav
MRO & Manufacturing
ITP Aero to Acquire Aero Norway, Expanding CFM56 MRO Services
ITP Aero signs agreement to acquire Aero Norway, enhancing aftermarket capabilities for CFM56 engines and expanding its European MRO presence.
ITP Aero, a global leader in aerospace propulsion, has signed a binding agreement to acquire Aero Norway, a specialized maintenance, repair, and overhaul (MRO) provider focused on CFM56 engines. According to the company’s official announcement, the transaction is expected to close during the first half of 2026, subject to customary regulatory approvals.
The acquisition represents a significant expansion of ITP Aero’s aftermarket capabilities. By integrating Aero Norway’s facility in Stavanger, Norway, ITP Aero aims to reinforce its status as a leading independent player in the aerospace services sector. The move follows a trajectory of aggressive growth for the Spanish propulsion company since its acquisition by Bain Capital in 22.
Aero Norway operates out of a facility at Sola Airport in Stavanger, employing a workforce of over 200 skilled technicians. The company has established a reputation for high-quality engine maintenance, specifically for the CFM56 engine family, serving a global client base of airlines, lessors, and asset managers.
In its press statement, ITP Aero highlighted that the two companies possess “highly complementary strengths.” The deal combines Aero Norway’s deep expertise in engine overhaul with ITP Aero’s existing engineering capabilities and component repair infrastructure. This synergy is designed to offer a more comprehensive suite of services to the aftermarket sector.
This agreement is the latest in a series of strategic moves by ITP Aero. In 2023, the company acquired BP Aero in the United States and was recently selected to join Pratt & Whitney’s GTF MRO network. These steps are part of a broader “2030 Strategic Plan” which aims to double the size of the business and increase the global workforce by 50% by the end of the decade.
While the press release focuses on corporate synergies, the acquisition underscores a critical trend in the current aviation landscape: the extended dominance of the CFM56 engine. As new-generation engines like the LEAP and GTF face supply chain delays and durability challenges, airlines are keeping older aircraft powered by CFM56 engines in service longer than originally planned.
Industry data suggests that approximately 20,000 CFM56 engines will remain in service through 2025. Consequently, the demand for maintenance shop visits is projected to peak between 2025 and 2027. By acquiring a specialist shop like Aero Norway, ITP Aero is effectively positioning itself to capture high-value work during this period of “structural undersupply” in the narrowbody market. This “Golden Tail”, the long, profitable tail end of an engine program’s lifecycle, provides a stable revenue runway for MRO providers capable of handling heavy overhauls. The crossover point where new-generation engine shop visits outnumber CFM56 visits is not expected until later in the decade, making capacity for legacy engines a premium asset today.
Leadership from both organizations emphasized the value of combining their respective technical strengths. Eva Azoulay, CEO of ITP Aero Group, described the agreement as a key component of the company’s roadmap.
“The signing of this binding acquisition agreement marks a significant milestone in our strategic roadmap. This acquisition reinforces our ambition to become a leading independent player in the aerospace aftermarket.”
, Eva Azoulay, CEO of ITP Aero Group
Neil Russell, CEO of Aero Norway, noted that the merger would unlock synergies beneficial to their customer base.
“By combining the complementary strengths of ITP Aero and Aero Norway, we will unlock significant synergies that enhance our competitiveness and deliver even greater value to our customers.”
, Neil Russell, CEO of Aero Norway
ITP Aero reports that it has tripled its earnings since 2022 and is currently implementing a long-term business plan that spans civil, defense, and MRO segments. The company was advised on legal M&A matters regarding this transaction by Baker McKenzie.
Pending regulatory clearance, the integration of Aero Norway into the ITP Aero Group will finalize in 2026, solidifying the company’s footprint in the European MRO market.
Sources:
ITP Aero to Acquire Aero Norway, Strengthening Position in CFM56 Aftermarket
Strategic Expansion in the MRO Sector
AirPro News Analysis: The “Golden Tail” of the CFM56
Executive Commentary
Future Outlook
Photo Credit: ITP Aero
MRO & Manufacturing
AkzoNobel Invests €50 Million to Upgrade US Aerospace Coatings Facilities
AkzoNobel invests €50 million to expand and modernize aerospace coatings production in Illinois and Wisconsin, enhancing capacity and supply chain resilience.
This article is based on an official press release from AkzoNobel.
AkzoNobel has officially announced a significant investments of €50 million (approximately $52–55 million) to modernize and expand its aerospace coatings capabilities in North America. According to the company’s announcement on December 18, 2025, the project will focus on upgrading its flagship manufacturing facility in Waukegan, Illinois, and establishing a new distribution center in Pleasant Prairie, Wisconsin.
This strategic move aims to increase production capacity and shorten lead times for airline and Maintenance, Repair, and Operations (MRO) customers. By enhancing its supply chain infrastructure, AkzoNobel intends to address the growing demand for air travel and the subsequent need for advanced aerospace coatings.
The investment centers on the Waukegan facility, which currently serves as AkzoNobel’s largest aerospace coatings production site globally. The site employs approximately 200 people and houses a dedicated color center. According to the press release, the capital injection will fund the installation of new machinery and automated processes designed to handle larger batch sizes.
To further optimize operations, the company is relocating its warehousing and distribution activities to a new facility in Pleasant Prairie, Wisconsin. This relocation is intended to free up floor space at the Waukegan plant, allowing for a focus on complex, customized chemical manufacturing.
Patrick Bourguignon, Director of AkzoNobel’s Automotive and Specialty Coatings, emphasized the forward-looking nature of the investment:
“This investment will increase our comprehensive North American supply capability and solidify our position as a frontrunner in the aerospace coatings industry. Demand for air travel is expected to grow significantly… and we want to make sure our customers are able to meet that demand.”
A key component of the upgrade is the introduction of a “Rapid Service Unit” dedicated to faster turnaround times for the MRO market. The company states that the new infrastructure will include a “liquid pre-batch area” and “high-speed dissolvers” to accelerate production.
Martijn Arkesteijn, Global Operations Director for AkzoNobel Aerospace Coatings, noted that these improvements are designed to enhance flexibility for customers: “We’ll be able to provide current and future customers with even more flexibility through the delivery of large batch sizes, better responsiveness to market needs and shorter lead time for color development.”
While AkzoNobel’s announcement focuses on internal efficiency, this investment arrives during a period of intensified competition within the North American aerospace sector. Earlier in 2025, rival manufacturer PPG announced a massive $380 million investment to construct a new aerospace coatings plant in Shelby, North Carolina.
In our view, AkzoNobel’s strategy differs significantly from its competitor’s greenfield approach. Rather than building new capacity from scratch, AkzoNobel is executing a targeted upgrade of existing assets. This “efficiency war” suggests that the company is betting on agility and technology upgrades, specifically the ability to deliver custom colors and small batches quickly via its new Rapid Service Unit, rather than simply expanding raw volume output.
The upgraded facilities are also aligned with the aviation industry’s push for decarbonization. AkzoNobel highlighted that the investment supports the production of its “Basecoat/Clearcoat” systems, which are lighter than traditional coatings. Reducing paint weight is a critical factor for airlines seeking to lower fuel consumption and carbon emissions.
Furthermore, the new automated processes are expected to reduce chemical waste and solvent use. The facility upgrades will likely support the increased production of chromate-free primers, meeting stricter regulatory requirements in both the United States and the European Union.
By localizing more storage and production capacity in North America, AkzoNobel also aims to bolster supply chain resilience, addressing vulnerabilities exposed during the post-pandemic aviation recovery.
AkzoNobel Announces €50 Million Upgrade to US Aerospace Coatings Operations
Strategic Expansion in Illinois and Wisconsin
Operational Efficiency and the “Rapid Service Unit”
AirPro News Analysis: The Competitive Landscape
Sustainability and Technology Integration
Sources
Photo Credit: AkzoNobel
MRO & Manufacturing
GE Aerospace Deploys 180 Engineers for Holiday Flight Operations
GE Aerospace positions 180 Field Service Engineers in 34 countries to prevent aircraft groundings and manage winter maintenance challenges during peak holiday travel.
While millions of travelers settle in for holiday downtime, the global aviation industry enters its most critical operational window. According to AAA projections, approximately 122.4 million Americans traveled 50 miles or more from home during the 2024-2025 holiday season, with air travel seeing a projected 2.3% increase in domestic flyers. Behind this surge lies a largely invisible workforce dedicated to preventing cancellations before they happen.
According to an official press release from GE Aerospace, the company deployed 180 Field Service Engineers (FSEs) to 34 countries specifically to support Airlines customers during this peak period. These engineers are “embedded” directly with airlines and airframers, working on tarmacs and in hangars to mitigate technical risks that could otherwise ground fleets during the busiest weeks of the year.
The role of an FSE goes beyond standard maintenance; it involves proactive problem-solving under strict time constraints. GE Aerospace describes these teams as being on the front lines, ensuring that both passenger jets and cargo freighters remain operational despite the strain of high-cycle usage and winter weather.
Jordan Mayes, a Regional Leader for GE Aerospace Commercial Field Service in Western Europe and Africa, highlighted the intensity of the holiday operational tempo in the company’s statement:
“The sense of urgency is more elevated than normal… And often there are fewer hands to do the work.”
, Jordan Mayes, GE Aerospace Regional Leader
This urgency is driven not just by passenger volume, but by a booming air cargo sector. Industry data indicates that air cargo volumes saw double-digit growth in late 2024, driven by e-commerce demands and shipping disruptions in the Red Sea. Stephane Petter, a Regional Leader for Central/Eastern Europe and Central Asia, noted that the stakes for cargo are often underestimated.
“An issue with a grounded or delayed passenger aircraft might delay 350 people. With a cargo plane, thousands of parcels might be delayed, so the downstream customer impact is potentially greater.”
, Stephane Petter, GE Aerospace Regional Leader
To illustrate the impact of embedded engineers, GE Aerospace shared a specific operational success story involving Alaa Ibrahim, the Middle East regional leader. His team was monitoring a Boeing 787 Dreamliner equipped with GEnx-1B engines. The engineers identified a minor clamp repair that was necessary to keep the engine compliant. The engine was only four cycles (flights) away from a mandatory 500-cycle inspection limit. If the limit was reached without the repair, the aircraft would be grounded, a disastrous outcome during peak holiday scheduling.
Instead of waiting for a forced grounding, Ibrahim’s team identified a six-hour window in the aircraft’s schedule. They performed the inspection and repair proactively, ensuring the aircraft remained available for service without disrupting the airline’s timetable.
Beyond scheduling pressures, FSEs must contend with the physical realities of winter aviation. Industry reports highlight that “cold soak”, where an aircraft sits in freezing temperatures for extended periods, presents unique mechanical challenges. Oil can thicken, and seals can shrink or become brittle.
According to technical data regarding modern engines like the CFM LEAP, specific warm-up protocols are required to thermally stabilize the engine before takeoff power is applied. Maintenance teams often switch to lower-viscosity fluids and rigorously check breather tubes for ice accumulation. If a breather tube freezes due to condensation, it can pressurize the engine and cause seal failures.
The deployment of these 180 engineers highlights a broader shift in aviation maintenance from reactive repairs to predictive intervention. By utilizing digital tools that monitor engine health in real-time, often referred to as “Flight Deck” principles, engineers can detect vibration trends or temperature spikes before they trigger a cockpit warning.
We observe that this strategy is particularly vital during the holidays. When load factors are near 100%, airlines have zero spare aircraft to absorb a cancellation. The ability of FSEs to turn a potential “aircraft on ground” (AOG) event into a scheduled maintenance task during a layover is the difference between a smooth operation and a headline-making travel meltdown.
All Sleigh, No Delay: How Field Service Engineers Keep Holiday Fleets Airborne
The “Invisible Elves” of Aviation
Operational Wins: The GEnx-1B “Save”
Technical Challenges in Winter Operations
AirPro News Analysis: The Shift to Predictive Maintenance
Frequently Asked Questions
Sources
Photo Credit: GE Aerospace
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