Air New Zealand has unveiled Hangar 4, a state-of-the-art aircraft maintenance facility that represents one of the airline’s most significant infrastructure investments. Forming part of the airline’s Auckland maintenance base in Māngere, Hangar 4 marks a bold step forward in operational capability and long-term growth strategy. Designed to serve the next 50 years of aviation, the new facility positions Air New Zealand at the forefront of modern fleet maintenance as it prepares for the arrival of next-generation aircraft.
At 10,000 square meters, 35 meters high and 98 meters wide, Hangar 4’s scale allows Air New Zealand engineers to service a Boeing 787-9 Dreamliner and two Airbus A320/A321s simultaneously, supported by an additional 5000 square meters of specialist workshops and engineering spaces. Cutting a striking figure on the South Auckland skyline, the hangar has already become a landmark of note for arriving travelers.
“This is a state-of-the-art facility that will enable us to maintain our fleet to the highest standards of safety and performance, while giving us the flexibility to adapt as aircraft technology evolves. This investment ensures we have fit for purpose, modern infrastructure for our engineers to service our fleet. The investment also signals our confidence in our future – in our people, our country, and in the proud role we play in connecting New Zealanders to each other and New Zealand to the world,” said Greg Foran, CEO, Air New Zealand.
An official opening event was attended by Prime Minister Christopher Luxon, who was chief executive officer of Air New Zealand when Hangar 4 was first announced in 2019.
“It’s great to see this project delivered and ready to help Air New Zealand in its role of driving tourism and trade,” Luxon said. “Infrastructure like this is critical for New Zealand, and Air New Zealand’s future. It supports highly skilled jobs and is future-fit for new innovation and growth.”
Innovation and sustainability at the heart of Hangar 4
Hangar 4, which is targeting a 6 Green Star Rating from the New Zealand Green Building Council, is the largest single-span timber arch aircraft hangar in the southern hemisphere. Timber was chosen for its lighter weight, ability to be sourced sustainably – from plantations in Nelson and Wodonga – and for its performance in a coastal environment.
Using cross‑laminated timber and laminated veneer lumber sourced locally by XLAM and Nelson Pine, the massive arches – each with up to 12,500 screws in individual trusses – were prefabricated into 25‑meter sections at a local plant. Secured with 250,000 screws across 20 trusses, the seismic‑resilient arch can flex up to 300 millimeters under earthquake loads, absorbing shock rather than resisting it.
In addition, an ETFE roof delivers natural light and retains heat without the need for a heating system, aided by ceiling fans that circulate warm air in winter and providing cooling in summer. Prefabricated trusses, each weighing 38 tonnes, were built in 25-meter sections, assembled on site and lifted into place using New Zealand’s largest crawler crane – a unique construction method at this scale.
