Chicago O’Hare International Airport continues to operate amid one of the largest redevelopment efforts at any U.S. hub, with the first new concourse under the ORDNext program now scheduled to open by the end of 2028. ([1])The $12.5 billion project aims to modernize facilities that have long constrained growth for its two primary carriers. American Airlines and United Airlines both plan meaningful increases in seat capacity from the airport this year even as a federal flight cap remains in place through at least October 2027.
Capacity Growth Despite Federal Limits
Schedule data show American Airlines increasing available seats by nearly 21 percent and United Airlines by more than 13 percent compared with 2025 levels. Departures are also rising, with American up 18 percent and United up 14 percent. These gains come while the Federal Aviation Administration maintains its order capping total flights to manage congestion.
Airlines are responding by deploying larger aircraft that carry more passengers per departure. The strategy allows carriers to expand their presence without violating the flight limit. Both airlines view the additional seats as essential to maintaining competitive positions at a hub that once ranked as the world’s busiest airport.
Key Construction Milestones Ahead
Concourse D, the first new facility under the current timeline, is expected to open with 19 gates by late 2028. Eighteen of those gates will accommodate either one wide-body aircraft or two narrow-body planes. The concourse will initially handle a mix of domestic and international flights, though full international arrivals processing will wait until the Global Terminal is finished.
Work on the Global Terminal itself is now slated to begin in 2029, with opening targeted for 2034. That represents at least a six-year delay from earlier projections. Concourse E, intended primarily for regional and single-aisle domestic operations, will follow in phases, with a northern segment of 14 gates due in 2030 and a southern segment of 10 gates around 2034.
Practical Benefits for Connecting Passengers
The new Global Terminal is designed to keep international arrivals and departures within a single secured area. Travelers connecting from overseas flights to domestic services will no longer need to exit security and travel between Terminal 5 and the main terminal complex. Officials have also noted the potential for expanded one-stop security arrangements that could eliminate a second screening for eligible passengers.
Designers have emphasized creating an immediate sense of place. The terminal is intended to reflect Chicago’s character from the moment passengers step off the aircraft. This approach contrasts with the more generic feel of the airport’s existing facilities and could improve the overall passenger experience during long connections.
Completed Work and Remaining Challenges
Several smaller projects have already opened, including a 10-gate expansion of Terminal 5 in 2023 and a three-gate addition to Concourse L. These incremental improvements have provided some relief while larger elements remain under construction. The overall program has encountered repeated setbacks, including pandemic-related disruptions and rising costs that pushed the original $8.5 billion budget higher.
The extended timeline reflects the complexity of building while maintaining operations at one of the nation’s busiest airports. City officials continue to view the completed project as vital to keeping O’Hare competitive with other major hubs served by American and United.
The redevelopment will eventually bring O’Hare close to 220 gates, a substantial increase from the 185 gates available in 2018. For travelers, the most immediate change will arrive with Concourse D in 2028, followed by further improvements that should streamline connections and support additional flight options in the years beyond.
