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India’s Aviation Growth Strains Hangar Capacity

India’s Aviation Growth Strains Hangar Capacity
Expanding Fleets Outpace Maintenance Infrastructure
India’s aviation sector is experiencing unprecedented growth, with airlines rapidly expanding their fleets and airports accelerating terminal development. However, a critical component of the aviation ecosystem—hangars and maintenance facilities—is failing to keep pace. As air traffic intensifies, the infrastructure necessary to maintain aircraft safety and operational readiness is emerging as a significant bottleneck.
A recent memorandum of understanding between Tata Projects Ltd (TPL) and Singapore-based Aircraft Support Industries (ASI) Global to design and construct aircraft maintenance facilities signals a strategic shift in addressing this challenge. Beginning in 2026, the focus will extend beyond fleet expansion and new routes to encompass the essential maintenance infrastructure required to sustain growth.
India’s fleet expansion is outstripping the development of its maintenance backbone, resulting in a growing deficit of hangar space across both civil and defence aviation sectors. This shortfall exposes aircraft to environmental damage, delays critical maintenance, and compels airlines to outsource heavy maintenance overseas. Such dependence on foreign maintenance, repair, and overhaul (MRO) providers is costly and strategically unsustainable. With the induction of wide-body aircraft accelerating and defence fleets undergoing modernization, the hangar shortage is evolving from a logistical inconvenience into a strategic vulnerability.
The Emerging Maintenance Challenge
Historically, India’s limited commercial fleet size and constrained budgets allowed the sector to operate with minimal hangar infrastructure. Routine line maintenance was often conducted outdoors, while major overhauls were outsourced internationally. This approach is no longer viable given the sector’s rapid expansion. The market for maintenance-grade hangars is entering a critical growth phase, driven by increasing commercial and business aircraft numbers, expanding airport capacity, and the introduction of new defence platforms. Concurrently, tightening global safety standards and a heightened focus on asset protection and operational reliability are intensifying the demand for adequate hangar facilities.
Rahul Sharma, executive vice president at Tata Projects’ Urban Spaces Strategic Business Unit, estimates that India will require at least three to four large MRO facilities within the next 15 years, representing an investment of approximately $6 billion. Without sufficient hangar capacity, aircraft remain vulnerable to environmental exposure, maintenance schedules are disrupted, and operators continue to rely on foreign service providers. Hangars are fundamental to any robust aviation ecosystem, safeguarding high-value assets, expediting maintenance processes, reducing costs, and ensuring fleet availability.
Despite these pressing needs, even flagship greenfield airports such as Navi Mumbai and Noida International have commenced operations without dedicated aircraft hangars, prioritizing terminals and runways over maintenance infrastructure. This trend underscores a broader imbalance: passenger capacity is expanding faster than the infrastructure required to maintain the aircraft serving those passengers. As wide-body operations increase and heavy maintenance continues to be outsourced, carriers like Air India and IndiGo will require climate-controlled hangars to protect their assets and develop in-house maintenance capabilities.
Operational Pressures and Strategic Implications
The strain on hangar capacity is exacerbated by additional operational challenges. Major carriers, including IndiGo, have faced disruptions due to airspace restrictions linked to geopolitical tensions and military escalations, resulting in widespread flight cancellations and diminished traveler confidence. In response, competitors are exploring strategic adjustments to mitigate operational risks and capitalize on emerging market opportunities. Meanwhile, leadership changes at Malaysia Aviation Group reflect a continued commitment to growth despite these headwinds.
As India’s aviation ambitions continue to ascend, the imperative for robust maintenance infrastructure becomes increasingly urgent. Without significant investment in hangar capacity and MRO facilities, the country risks undermining the very growth it aims to achieve in the global aviation arena.

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