Hangar 4

Air New Zealand’s new Hangar 4 facility at Auckland Airport is one of the airline’s most significant infrastructure investments. Designed to service the national carrier’s fleet over the next 50 years, the 10,000sqm facility increases capacity, efficiency and resilience across aircraft maintenance operations.

Hangar 4 is the largest single-span timber aircraft hangar in the Southern Hemisphere. It has the capacity to service one Boeing 787-9 and 2 Airbus A320 aircraft simultaneously, alongside 5,000sqm of specialist engineering areas and workshops.  Underground service pits remove the need for surface cabling, improving operational safety and flexibility. The Hangar is also integrated with the adjacent Hangar 3 through shared workshops and tool stores to support streamlined operations.

Innovation and Sustainability

Hangar 4 targets a 6 Green Star rating. Timber was chosen for its lighter weight, durability in coastal conditions, and sustainable sourcing from plantations in Nelson and Wodonga. An ETFE roof delivers natural light and helps regulate temperature, retaining heat in winter and cool air in summer.

The prefabricated timber trusses, each weighing 38 tonnes, were built in 25-metre sections, assembled on site and lifted into place using Aotearoa’s largest crawler crane – a unique construction method at this scale.

Our role

TSA Riley led project management through design, procurement, and delivery. Our work focused on programme and delivery strategy, coordination of design and construction teams, risk management, safety assurance, and stakeholder engagement.

The scale, complexity and operational requirements of the hangar necessitated a highly collaborative delivery environment. Our team worked closely with Air New Zealand to balance functionality, sustainability and constructability, helping bring the vision for Hangar 4 to life.