UK MROs Expand Capacity Ahead Of Winter Demand

As the winter season begins, UK-based independent MRO providers are stepping up their operations to meet growing demand for aircraft maintenance.

Caerdav and BCT Aviation Maintenance are both expanding their capacity and upgrading equipment to handle a busy season focused on narrowbody aircraft.

The launch of a fourth maintenance line at Caerdav’s Twin Peaks site at St. Athan in Wales earlier in November signals a major step forward in the company’s ongoing expansion strategy. The move effectively doubles Caerdav’s capacity within 18 months, enabling the independent MRO to accommodate four aircraft simultaneously. The expansion follows extensive remodeling of hangar space and back shop capabilities, allowing for a broader range of in-house services including composite repairs, non-destructive testing, and paint restoration.

“As airlines continue to grow their fleets, we don’t see an end to the current high levels of demand for heavy base maintenance,” Phil Swanson, commercial director at Caerdav tells Aviation Week. The Wales-based MRO is exploring opportunities to expand the business even further, with Swanson hinting at further expansion plans.

Caerdav anticipates that the new line will be particularly valuable for structural work on aging narrowbody aircraft. “We are seeing growing numbers of heavy maintenance checks requiring structural repairs and modifications,” Swanson says. “Our new fourth line will be truly valued by customers, with our ability to deploy experienced structural engineers.”

Swanson notes that persistent supply chain issues at Airbus and Boeing have led to a shortfall in new aircraft deliveries, especially for narrowbody types like the Boeing 737 and Airbus A320. As a result, airlines are operating older fleets for longer, driving up demand for more extensive and frequent maintenance.

Caerdav says it continues to prioritize operational efficiency, with its engineering teams streamlining tasks like cabin strip and rebuild through experience gained from ongoing work with major airline clients. “The engineering teams keep finding new ways to work faster and more efficiently—without compromising on safety or quality—helping to deliver competitive turnaround times,” Swanson says.

Workforce development is also central to Caerdav’s strategy. The company’s aerospace apprenticeship program continues to grow, with its fourth cohort beginning training in September. “Some of our very first graduate apprentices have already been promoted to aviation technicians,” Swanson says.

Meanwhile, BCT Aviation Maintenance is preparing for a full-capacity winter program at East Midlands Airport, with 12 737NG aircraft scheduled for checks between October and March 2026. The company has made a six-figure investment in hangar equipment and electric vehicles, and other equipment.

“This major investment further demonstrates BCT’s commitment to the growth of the company,” a spokesperson said in a media statement to Aviation Week. “It also supports our ongoing development and investment in continuously enhancing our base maintenance service offering.”

BCT’s strategy includes equipment hire on bespoke terms, targeting UK-based airlines and MROs. The company also highlights operational benefits from owning its equipment. “Our engineering personnel are well trained and familiar with its usage, which enhances overall safety in the workplace,” BCT adds. “This has the added benefit of providing better access to the required equipment, reduced delays and improved efficiency.”

As both MROs gear up for the winter season, their investments highlight key industry shifts—older aircraft staying in service longer, fewer new jets being delivered, and a growing need for faster, flexible maintenance options.