Challenge

As part of the Terminal 5 Expansion and Modernization project at Chicago O’Hare International Airport, our team was responsible for restriping all new gates and hardstands. The Chicago Department of Aviation (CDA) needed to ensure that every aircraft type expected to use these positions could be properly accommodated, while also maintaining consistent striping standards across the terminal. The incorporation of Multiple Aircraft Ramp System (MARS) gates added further complexity, requiring highly detailed paint marking plans and flexible gate layout solutions.

Solution

Our team collaborated closely with project designers, gate controllers, and the CDA to identify which aircraft would operate from each new position. Using this information, we developed precise striping plans tailored for each gate, accounting for considerations such as wingtip clearances, fueling access, jet bridge alignment, and pushback procedures. Each plan included detailed coordinates, lead-in lines, and stop-bar locations, enabling painters to execute the striping accurately and efficiently.

Outcome

The expansion opened with 10 new widebody gates and 14 narrowbody positions, giving Terminal 5 its highest operational capacity to date. Beyond supporting immediate needs, this effort also established standardized practices for airfield striping at O’Hare, creating a consistent framework to guide future gate design and layout.