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.
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:
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:
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:
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.
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
“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
| Category | Details |
| Application Type | Aircraft maintenance hangar (MRO facility) |
| Client | TIM Aerospace |
| Contractor | RACQ Contracting |
| Consultant Engineer | Model Engineering |
| Fibre Type |
AFT®+09/60 |
| Slab Area | 18,000 m² |
| Slab Depth | 260 mm |
| Completion Date | June 2025 |
| Location | Dubai South, Dubai, UAE |
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: 28th Floor, The One Tower, Dubai, UAE