New renderings and a detailed fly-through video are providing a clearer look at the upcoming Concourse D at O’Hare International Airport, marking the first major airport expansion since the completion of Terminal 5 in 2023. The project represents the opening phase of the larger ORDNext modernization program, with completion of the concourse targeted for 2028.
For contractors, engineers, and suppliers, projects of this scale represent complex coordination across structural systems, utilities, passenger circulation infrastructure, and aviation operations. Large airport expansions require precise sequencing and logistical planning, particularly when construction occurs adjacent to active runways and terminals.
Concourse D will be located southwest of the existing Concourse C and connected through an elevated tunnel. This connection is a key component of passenger flow, allowing travelers to move efficiently between concourses while maintaining security separation and operational continuity.
Chicago Yimby reports that the new concourse will span approximately 580,000 square feet and include 19 new gates. These gates are designed with flexibility in mind, allowing configurations that accommodate a range of aircraft sizes, including widebody planes used for long-haul international routes. Designing gates that can handle multiple aircraft types requires careful coordination of structural spacing, jet bridge placement, apron geometry, and fueling and service connections.
At the center of the concourse will be a major architectural feature known as The Orchard. This large circular hub will provide roughly 30,000 square feet of lounge areas, dining, retail, and seating spaces. The concept draws inspiration from the airport’s historical name, Orchard Field, and incorporates branching structural columns that mimic trees. These columns will support ceilings rising to approximately 40 feet, creating a spacious interior environment while carrying significant structural loads.
Another critical design feature is the suspended sterile corridor, which will allow arriving international passengers to move securely to a future passport control facility. Designing elevated corridors within an airport environment requires specialized structural engineering, vibration control, and fire protection planning to ensure both safety and operational efficiency.
Large windows at the south end of the building will frame views toward the city, while also introducing natural light deep into the concourse. Curtain wall systems in aviation buildings must balance aesthetics with energy efficiency, thermal performance, and glare control, particularly in areas exposed to large expanses of sunlight.
Future phases of the ORDNext program will connect Concourse D to the new Global Terminal and Concourse E through an underground tunnel. Planning these connections in advance ensures that structural and utility alignments are coordinated early, reducing costly modifications later.
Construction on Concourse D began in early 2025 with site preparation, underground utility installation, and tunneling operations. These early phases are often the most complex in airport environments, requiring relocation or protection of existing utilities, coordination with airfield operations, and strict adherence to safety and security protocols.
Underground work includes stormwater systems, electrical duct banks, telecommunications infrastructure, and mechanical systems needed to support terminal operations. Tunneling activities must also account for soil conditions, groundwater management, and structural support systems that prevent settlement affecting nearby facilities.
With heavy equipment already mobilized on site, vertical construction is expected to advance soon. Structural steel erection, concrete placement, and envelope installation will follow in carefully sequenced phases to maintain schedule and safety.
Airport concourses demand durable materials capable of handling heavy passenger traffic and high maintenance requirements. Structural steel framing, reinforced concrete foundations, and large-span roof systems are typically used to achieve wide column spacing and flexible interior layouts.
Interior finishes must also withstand heavy use, including terrazzo or stone flooring, high-durability wall systems, and modular ceiling assemblies designed for maintenance access. Mechanical, electrical, and plumbing systems in aviation terminals are particularly complex, as they must support lighting, climate control, baggage systems, communications infrastructure, and security technologies simultaneously.
Energy efficiency and operational reliability are also key priorities. Large airport buildings incorporate advanced HVAC systems, high-efficiency glazing, and integrated building automation systems to reduce operating costs and maintain comfort across large interior volumes.
The ORDNext program will ultimately increase gate capacity by approximately 14 percent, a significant upgrade as O’Hare continues to rank among the busiest airports in the United States. In 2025 alone, the airport recorded more than 857,000 aircraft movements.
This expansion also comes at a time of increased competition among major carriers operating at O’Hare. As airlines expand routes and fleet capacity, infrastructure projects such as Concourse D play a crucial role in maintaining operational efficiency and accommodating future growth.
In parallel with construction, O’Hare is preparing to award one of the largest concessions contracts in the nation, covering 110 commercial locations across Terminals 1 and 3. Coordinating tenant build-outs with major structural construction adds another layer of scheduling complexity to the project.
A project of this scale requires coordination among many skilled trades and specialties, including:
Concourse D represents more than a new terminal extension. It demonstrates how modern airport construction blends engineering, architecture, and logistics to create infrastructure capable of handling millions of passengers efficiently and safely.
As construction progresses toward 2028, the project will continue to showcase the scale, coordination, and craftsmanship required to deliver complex aviation facilities. For contractors and construction professionals, projects like this highlight how planning, sequencing, and technical expertise come together to shape the next generation of transportation infrastructure.