Airport Diseconomies of Scale​

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  • August 07, 2025

Introduction

Airport diseconomies of scale​

The scale of an airport can significantly influence its efficiency, cost structure, and overall profitability.​

While existing research on airport economies of scale largely focuses on smaller facilities, there is limited analysis on whether these benefits persist—or begin to reverse—at higher traffic volumes. Yet observations suggest that very large airports, particularly those exceeding 40 million WLU (Work Load Unit—either 1 passenger or 100kg of air cargo, and can be either departing from or arriving at the airport) annually, often incur disproportionately high costs.​

Development of mega hubs around the world​

In recent years, global aviation has witnessed significant growth, resulting in many large airports. In 2001, only eight airports worldwide handled more than 40 million passengers per annum (mppa); by 2019, that number had risen to 56, with numerous plans underway to develop mega-airports designed for over 100 million WLU annually. However, it remains unclear whether such large-scale infrastructure delivers the expected efficiencies—or whether the additional complexities risk triggering cost escalations instead.​

Hence, new analysis on airport diseconomies of scale is needed, particularly in the context of new airport infrastructure development and post-COVID recovery of the aviation sector.​

Overview of airport scale development over the past 20 years​

During the last two decades, the number of large airports (>40 million passengers per annum, mppa) has increased rapidly. The Asia-Pacific region, especially China, contributed the largest percentage of this growth.​

 

24

more airports in Asia-Pacific with traffic >40 mppa (from 1 in 2001 to 25 in 2019)

43.5% growth in traffic contribution of APAC airports with >40 mppa to global airports with >40 mppa in 2019

Airports across Asia-Pacific are undergoing significant expansions, with many targeting capacities of 100 million passengers per annum (mppa) or more to meet rising demand and establish themselves as global hubs.

Major ongoing expansions include Bangkok Suvarnabhumi airport (150 mppa by 2033) and Beijing Daxing airport (100 mppa by 2040). New mega airports like New Manila and Long Thanh are each designed to eventually handle 100 mppa. Similarly, Kuala Lumpur International Airport has long-term plans for up to 140 mppa, while Hong Kong International Airport aims to serve 120 mppa in around 10 years through its Three Runway system.​

The development of large airports can be justified for various reasons:​

Urbanisation & population growth​

Commercial incentives​

Prestige & geopolitical influence​

Location & lack of alternatives​

Socioeconomic benefits​

Connectivity

Key findings

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Assessing diseconomies of scale of airports: Relevant stakeholders​

  • With the advent of new aircraft generations that are smaller and have extended flight ranges, mid-sized airports are now capable of handling long-haul flights and are also well-suited to meet the growing demand for regional jets.​
  • Mid-sized airports generally have shorter taxi times, less congestion, and more efficient gate use, translating to reduced operating costs and better on-time performance.​
  • Mid-sized airports provide a more pleasant, efficient journey due to their simpler layouts and shorter walking distances between key areas such as check-in counters and gates, which can improve the overall passenger experience.
  • In comparison, large airports have more delays, long walking distances, increased land travel distances, and lower passenger satisfaction.
  • The infrastructure required for large airports involves substantial capital investment, which can place significant strain on government budgets, either directly, or via absorbing PPP capacity in the country​.
  • Upgrading and expanding facilities at large airports, such as runways and air navigation systems, also demands considerable financial resources.​
  • While most environmental discourse focuses on flight-related (Scope 3) emissions, the direct (Scope 1) and energy-related indirect (Scope 2) emissions of airports themselves also represent a measurable carbon footprint.​
  • Mid-sized airports are best positioned to achieve balance between size, infrastructure complexity, and operational demand that avoids the high fixed energy use of small airports and the more complex, energy-intensive systems of large airports.
  • Mid-sized airports often outperform larger hubs on financial metrics like ROA, ROCE, and ROIC, as they tend to be more agile and require less costly upgrades than mega hubs.
  • Investors prefer mid-market infrastructure like mid-sized airports due to more predictable cash flows and manageable risk. These airports are less exposed to demand shocks and congestion risks compared to mega hubs.​

Conclusion

We recommend that policy makers, planners and airport developers expand their focus beyond merely addressing capacity to meet demand. Instead, they should evaluate options for delivering a cost-effective travel experience for passengers. These options should consider factors such as surface travel distances to the airport, the time spent navigating the airport from curbside to aircraft, and the operational efficiencies that airlines achieve with shorter taxi distances from runway to gate. Additionally, the availability of slots that align with passenger and airline schedules should be taken into account.​

Undertaking the development of mega-hub airports is not a guaranteed success. Such projects entail significant challenges related to connectivity, operational efficiency, and the complexity of overall management. Ensuring optimal performance and satisfaction for all stakeholders presents considerable difficulties in the context of large-scale airport operations.​

Secondary or mid-sized airports with terminal capacities of 15-40 mppa can provide more sustainable air connectivity growth compared to mega hubs. There are many growth opportunities at secondary or mid-sized airports, with more efficient management of return and expense, and better implication for various relevant stakeholders.

Considerations for policy makers and airport developers​

  • Identifying inefficiencies and developing targeted solutions to reduce the impact of airport size on profitability and efficiency.​
  • Building smaller airports in multiple locations, investing in technology and automation to resolve diseconomies of scale issues​.
  • Promoting environmentally sustainable practices​.
  • Forming partnerships with neighbouring airports​
  • Developing policies to encourage airlines to use regional airports​
  • Working with hub airlines to optimise their operations and costs at the airport​

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Airport Diseconomies of Scale

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Edward Clayton

Partner, Deals Strategy & Operations, PwC Malaysia

Tel: +60 1 6672 3420

Amrul Zeflin Anim

Deals Director, Capital Projects and Infrastructure, PwC Malaysia

Giang My Huong

Director, Capital Projects and Infrastructure, PwC Vietnam

Tel: +84 976 065 886

Huynh Ngoc Khanh Linh

Manager, Capital Projects and Infrastructure, PwC Vietnam

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Yin-Shyen Chong

Manager, Capital Projects and Infrastructure, PwC Malaysia

Tel: +60 1 0390 0312

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