Recognising the strategic importance of air connectivity, the New Zealand Government funded a major expansion programme to extend and strengthen the runway, enabling the airport to accommodate long-haul jet operations and ushering in a new era of accessibility for the islands.
The primary driver for the upgrade was the need to support direct jet services, including Boeing 707 flights from Auckland. This capability dramatically reduced travel times, improved reliability, and positioned Rarotonga as a viable international destination. The investment not only enhanced aviation safety and operational capacity but also played a critical role in stimulating the Cook Islands’ tourism industry, strengthening economic links with New Zealand and the wider Pacific region.
For McKay, the Rarotonga International Airport upgrade represented a significant milestone as the company’s first overseas project. Building on experience gained at Queenstown and Te Anau Airports while operating in the South Island during the Aluminium Smelter project, McKay was engaged to deliver a comprehensive scope of high-voltage, low-voltage and airfield electrical works. Although technically well within the company’s capabilities, the project presented the added complexity of operating in an overseas environment for the first time.
McKay’s scope included the supply, installation and termination of an 11 kV power supply system incorporating three power centres. This encompassed the installation, testing and commissioning of all 11 kV switchgear and transformers, as well as the complete 400-volt distribution system, including switchgear and cabling. To ensure operational resilience, McKay also supplied, installed, tested and commissioned two 150 kVA stand-by diesel alternators together with all associated control equipment.
Airfield lighting formed a critical component of the project. McKay completed the full installation of lighting for the new 8,000-foot runway, including 200 runway edge and taxiway lights, 161 runway centreline lights and a T-VASIS system to support safe aircraft approach and landing. In addition, the project included the supply and installation of 55 street lights along approach roads and throughout car park areas, improving safety and accessibility across the airport precinct.
The works extended to the complete electrical installation of all air facility buildings and a new hangar complex, supporting both operational and maintenance requirements. Across the site, approximately 150,000 metres of underground cabling of various sizes were installed, reflecting the scale and complexity of the electrical network. Careful coordination was required to schedule the delivery of equipment and ensure all installations were completed in parallel with the overall construction programme, allowing the airport upgrade to be commissioned as a fully integrated facility.
As part of the project deliverables, McKay supplied complete sets of computer-aided drawings covering all installed plant and equipment, providing a comprehensive and enduring record for future operation and maintenance. Delivered over several years by teams deployed to Rarotonga, including Graeme Clarke and Noel Driver, the project not only established McKay’s offshore capability but also laid the groundwork for many future projects across the Pacific Islands.
The Rarotonga International Airport upgrade remains a landmark achievement, both in creating a modern international gateway for the Cook Islands and in marking the beginning of McKay’s long-standing involvement in delivering complex electrical infrastructure projects beyond New Zealand’s shores.
