Project Highlight: FlightSafety International Columbus Learning Center Expansion
25+ Year Relationship
Miller Valentine recently completed the latest expansion at FlightSafety International’s Columbus Learning Center, continuing a long-standing partnership that began in 1999. Over the years, Miller Valentine has worked with FlightSafety in multiple capacities and has constructed all three major expansions at this facility, including the original building in 2014, a Phase II expansion in 2017, and this most recent addition. The latest project was driven by increasing demand for pilot training, prompting the need for additional simulator bays and classroom space to support the center’s growing operations. Construction began in December 2024 and was completed in November 2025, delivering the new expansion in time for the arrival and installation of new training equipment.
Challenges
A key challenge of the project was working around FlightSafety’s 24/7 operations while meeting strict FAA requirements for ambient noise in the simulator and classroom environments. To prevent disruption to ongoing training sessions, Miller Valentine coordinated closely with the FlightSafety team to schedule certain high-impact tasks during off-hours. This included activities such as installing rammed aggregate piers on a continuous 24/7 schedule for four days, cutting openings through existing concrete panels to connect the expansion to the current facility, and conducting building system inspections, including fire alarm, sprinkler, and pre-action fire systems, between 2:00 and 4:00 a.m. Achieving this level of coordination required weekly and sometimes daily reviews of FlightSafety’s training schedule to ensure construction activities did not interfere with classes or simulator operations.
Meeting Client Priorities
FlightSafety’s top priority was maintaining uninterrupted operations in the existing facility while ensuring the expansion was completed ahead of equipment delivery. One example of this close coordination occurred during the installation of the roof decking, which required powder-actuated fasteners that produce repeated loud “popping” sounds. To confirm the activity would not impact training sessions, Miller Valentine staged the trade partner on the roof while team members coordinated with FlightSafety staff positioned throughout the building to monitor noise levels in real time. Once it was confirmed that the activity would not affect training, the work proceeded as planned.
During the construction of the expansion, Miller Valentine was also asked to complete several interior upgrades within the occupied facility, including a full renovation of the front lobby as well as new flooring and lounge finishes in common areas. Because this work occurred in active training spaces, the team developed a detailed sequencing plan for overnight crews, allowing FlightSafety to adjust class schedules as needed. The lobby renovation was completed in two phases to keep the main entry operational during business hours, minimizing confusion for clients and visitors while construction progressed.
The completion of this project further strengthens Miller Valentine’s long-term relationship with FlightSafety International and demonstrates the team’s ability to deliver complex construction projects in highly active environments. With this final expansion, the Columbus Learning Center has grown from housing six simulators when it first opened to 14 after the 2018 expansion and now to a total capacity of 20 simulators, significantly expanding the facility’s ability to meet the growing demand for pilot training.
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