Taking Floor Slabs to a New Level

Twintec was appointed to design and construct high-performance Twintec’s Freeplan® jointless concrete floor slabs for the TIM Aerospace MRO facility located in Dubai South. The facility will operate as an aircraft maintenance, repair and overhaul (MRO) centre, accommodating a wide range of commercial aircraft types and demanding operational loads 

The project comprised approximately 18,000 m² of internal hangar flooring, engineered to withstand defined aircraft wheel loads and tripod jacking forces while maintaining consistent flatness and long-term durability. Working closely with the main contractor, RAQ Contracting, Twintec delivered a value-engineered flooring solution under a highly compressed schedule.

Optimised Design for Aircraft Loading

Aircraft hangar concrete floor slabs present a unique structural challenge, combining large open spans with exceptionally high point loads. In addition to aircraft wheel loads, the slab design had to accommodate tripod jacking systems used during maintenance operations, where concentrated loads are transferred through individual jack legs.

Twintec provided full structural design, material supply, and execution of the ground-bearing slab, including:

• Structural design calculations in accordance with TR34
• Detailed construction drawings
• Supply of steel fibres, armoured joints, dry-shake topping, and curing systems

The slab was designed to an FM2 flatness tolerance, appropriate for hangar operations, while prioritising load performance and durability over large, jointless panels.

Key design features included:

• A uniform slab thickness of 260 mm optimised through value engineering
• Large jointless panel sizes up to 35 m × 35 m
• Reduced joint frequency to minimise long-term maintenance
• Use of AFT® + 09/60 steel fibres selected for their high tensile strength and structural contribution under extreme point loads

Fibres were integrated onsite using a high-performance fibre integration machine, to ensure consistent distribution and quality throughout all pours.

This rapid delivery was enabled by the Twintec’s Freeplan® jointless system, which allowed for:

• Larger panel pours
• Reduced joint installation and preparation
• Minimal site preparation between pours

Construction was carried out using flood pour techniques, laser screed technology, and topping spreader application to achieve consistent levels and surface finish across the expansive hangar areas.

A key on-site challenge was the presence of large open hangar doors during casting, creating exposure to environmental conditions that would typically be avoided. Twintec mitigated this through careful planning, material selection, and the use of finishing aids commonly deployed in the region to maintain surface quality under open-building conditions.

Value Engineering and Quality Delivery

Twintec’s involvement delivered measurable value by significantly reducing slab thickness compared to originally envisaged traditional reinforced solutions, while still meeting all structural and operational requirements. This value-engineered approach provided cost efficiencies, faster construction, and a robust long-term flooring solution tailored to the demands of aircraft maintenance operations.

The completed floor has been noted for its high-quality finish and detailing, particularly around complex interfaces such as service pits and hangar door thresholds. The project has already served as a live reference, with visiting clients and consultants providing positive feedback on the quality and performance of the finished slab 

Client's Reflection

“This project demonstrates how effective value engineering and jointless slab design can deliver both performance and faster construction, when all project stakeholders work together. Despite the demanding load conditions and accelerated schedule, the quality of the finished floor is something Twintec can be very proud of.”  Ahmad Al Rababah, Operations Manager, RAQ-Ops

 Project Insights

Speak with our Twintec Middle East specialists to explore how we can support your next aviation, logistics, or industrial flooring project with proven jointless solutions.

Contact: Jamie Snowdon

Tel: +971 (4) 364 1216 / 1220

Email: j.snowdon@twintecgroup.com

Regional Office: 28^th Floor, The One Tower, Dubai, UAE