Industrialized Aluminium Construction: How Gaptek Technology Works

Industrialized construction is transforming the way large-span buildings are developed for the aerospace, defense, healthcare, and industrial sectors. At Gaptek, we have spent more than 15 years developing our own proprietary technology based on high-performance aluminium structures, enabling us to design, manufacture, and build permanent buildings that are lighter, more efficient, and more sustainable than traditional construction systems.

Our technology combines engineering, industrialized manufacturing, and turnkey project delivery to reduce construction times, optimize logistics, and minimize maintenance costs throughout the building’s lifecycle.

In this article, we explain how our technology works, the advantages it offers over traditional steel construction, and why it has been selected for projects in some of the world’s most demanding environments.

What Is Gaptek Technology?

Gaptek Technology is our proprietary industrialized construction system, developed to design and build permanent large-span buildings that combine lightweight structures, rapid installation, sustainability, and outstanding structural performance.

After more than 15 years of research and development, we have created a construction system based on proprietary high-performance structural aluminium profiles, entirely designed by our engineering and architectural teams.

Our technology enables the construction of permanent buildings for applications where construction speed, logistics, reliability, and operational performance are critical, including:

• • • Aircraft hangars
    • Defense facilities
    • Industrial buildings
    • Logistics centers
    • Healthcare infrastructure

What Makes Gaptek Technology Different?

Our competitive advantage is not simply the use of structural aluminium.

The real difference lies in a construction system specifically engineered to optimize the entire building lifecycle.

Its main advantages include:

• • • Over 15 years of proprietary technology development
    • High-precision industrialized construction
    • Significantly lighter structures
    • Optimized worldwide transportation
    • Fast and safe installation
    • Reduced maintenance costs
    • Lower environmental impact
    • Permanent yet relocatable buildings
    • Fully customized designs
    • Complete turnkey project delivery, from engineering to lifecycle maintenance

Gaptek Technology vs. Traditional Steel Construction

Traditional steel construction remains an excellent solution for many applications. However, for specific projects, structural aluminium provides significant technical, logistical, and economic advantages.

Benefits of Building with Gaptek Technology

Our technology delivers measurable benefits throughout every stage of a project’s lifecycle—from design and logistics to construction, operation, and long-term maintenance.

Lightweight Structures

Gaptek’s structural aluminium technology can reduce structural weight by up to 60% compared to equivalent steel solutions. This lower weight minimizes foundation requirements, reduces lifting equipment needs, and simplifies transportation and installation.

Faster Construction

Our industrialized construction system significantly shortens project schedules through off-site manufacturing, standardized components, and mechanical connections that eliminate on-site welding.

This approach reduces installation time while improving construction quality and predictability.

Lower Environmental Impact

By using recycled aluminium, our technology can reduce the building’s carbon footprint by up to 21% compared to conventional steel construction.

The result is a more sustainable solution aligned with modern environmental standards and decarbonization objectives.

Reduced Maintenance Costs

Unlike steel, aluminium naturally forms a protective oxide layer that prevents corrosion without requiring additional treatments or periodic repainting.

This substantially lowers maintenance requirements and reduces lifecycle costs.

Permanent Yet Relocatable Buildings

Gaptek buildings are designed as permanent structures while retaining the ability to be dismantled, transported, and reassembled whenever operational requirements change.

This flexibility allows clients to protect their long-term investment.

Supporting the Circular Economy

Aluminium retains its mechanical properties through multiple recycling cycles, making it one of the most sustainable structural materials available and supporting circular construction principles.

Improved Energy Efficiency

Our buildings incorporate insulated envelope systems and high-performance building solutions that improve thermal performance, reduce energy consumption, and create more comfortable indoor environments.

Turnkey Project Delivery

Gaptek manages every phase of the project through a single point of contact, including:

• • • Engineering
    • Architectural Design
    • Manufacturing
    • Construction
    • Lifecycle Maintenance

Certified Quality

Our processes comply with internationally recognized standards, including:

• • • ISO 9001
    • ISO 14001
    • ISO/IEC 27001
    • EN 1090-3
    • ASCE Standards

We make reality your project

Know our capabilities. We invite you to see our corporate video. Do not hesitate to contact us, we will be proud to help you make your project come true.

Wide-Body Aircraft Hangars: The Five Technical Requirements That Define a Successful MRO Project

When an airline, Maintenance, Repair and Overhaul (MRO) provider, or defense organization plans the construction of a new wide-body aircraft hangar, the first question is usually:

How large does the building need to be?

While dimensions are important, they are only one part of the equation.

The long-term success of an aircraft hangar depends on several engineering decisions that determine operational efficiency, construction speed, sustainability, and future flexibility.

As the global demand for aircraft maintenance continues to grow, operators increasingly require facilities that can be delivered quickly without compromising quality or operational performance. Industrialized construction systems have become an effective solution, allowing large clear-span buildings to be assembled faster while maintaining the structural performance required by modern aviation facilities.

The wide-body hangar developed by Gaptek for Fokker Services Group in Woensdrecht, the Netherlands, is an excellent example of how industrialized construction can successfully meet the demanding requirements of aircraft such as the Airbus A330, Airbus A350, and Boeing 777.

Why Wide-Body Aircraft Require a Different Hangar Design

1. Large Clear-Span Structures Without Interior Columns

One of the most critical requirements for any MRO facility is a completely unobstructed interior.

Interior columns reduce operational flexibility, complicate aircraft movements, and interfere with maintenance activities.

Industrialized aluminum structures allow engineers to achieve large clear spans while reducing the overall structural weight, minimizing foundation loads and simplifying construction.

The Fokker Services Group hangar provides approximately 7,400 square meters of unobstructed operational space within an 87 × 86-meter footprint, allowing maintenance operations on large commercial aircraft without structural interference.

This design significantly improves workflow efficiency while offering greater flexibility for future operational changes.

2. Proper Building Height and Advanced Door Systems

Aircraft size also determines the minimum building height.

Maintenance operations on wide-body aircraft require sufficient vertical clearance for tail access, elevated work platforms, lighting systems, and overhead lifting equipment.

Door design plays an equally important role.

Modern multi-leaf door systems allow operators to open only the required sections, minimizing heat loss, reducing energy consumption, and improving operational efficiency during aircraft movements.

The Woensdrecht facility incorporates translucent multi-leaf doors that maximize natural daylight while improving the building’s overall energy performance.

3. Integrated Material Handling Systems

An aircraft hangar is much more than a protective enclosure.

It is a highly specialized industrial workspace where engines, landing gear, and large aircraft components are routinely removed, installed, and transported.

For this reason, lifting systems should be integrated into the structural design from the earliest engineering stages.

Typical integrated systems include:

• • • Overhead cranes
    • Electrical distribution
    • Compressed air networks
    • Technical lighting
    • Maintenance utilities

The Fokker Services Group hangar incorporates a 7.5-ton overhead crane suspended directly from the primary structure, providing efficient handling of heavy aircraft components while maximizing usable floor space.

We make reality your project

Know our capabilities. We invite you to see our corporate video. Do not hesitate to contact us, we will be proud to help you make your project come true.

We make reality your project

We make reality your project

Gaptek Drives Innovation in Aviation Infrastructure at MRO Middle East 2026

Gaptek once again participated in MRO Middle East 2026, reinforcing its positioning as a strategic partner in industrialized infrastructure solutions for the aviation sector. The event took place on February 4–5, 2026, at the Dubai World Trade Center, confirming its role as a key meeting point for leading players in aircraft maintenance, repair, and overhaul (MRO).

Our presence at this edition reaffirmed Gaptek’s commitment to innovation, operational excellence, and the development of high value-added solutions for the industry. Throughout the event, we showcased our capabilities in the design and construction of hangars, warehouses, and other specialized aviation infrastructures, with a strong focus on operational efficiency, sustainability, and fast-track execution.

We make reality your project

As we approach the end of the year, we would like to extend our sincere thanks to our clients, partners and collaborators for the confidence placed in Gaptek throughout 2025.

This year has been defined by strategic projects, international collaboration and sustained development across key markets in Europe, the Middle East and the United States. Each achievement reflects the strength of long-term partnerships and a shared commitment to technical excellence, reliability and performance.

We make reality your project

At Gaptek, we are truly honored to be featured in the 2025 Aeronautical Yearbook by the magazine Airline Ninety Two, a key reference for the aeronautical industry in Spain and Latin America. This prestigious publication highlights the companies and initiatives that are shaping the present and future of the sector, and we are proud to be part of this select group.

This recognition is both an encouragement and a responsibility. It motivates us to continue working with the same passion, commitment, and sense of purpose that define our daily efforts. At Gaptek, we believe in the power of innovation, agility, and collaboration to respond to the growing demands of a constantly evolving industry.

Our inclusion in this edition reinforces our position as a strategic actor within a sector undergoing deep transformation—driven by sustainability imperatives, rapid technological progress, and the challenges of a more connected and globalized world.

We are particularly proud of the impact our modular and innovative solutions are having across key areas such as airport, military, and industrial infrastructures.

We make reality your project

Gaptek has been included in the sixth edition of the Spanish Defense Industry Catalog, an initiative promoted by the Ministry of Defense through the Directorate General of Armament and Material (DGAM).

The main objective of this publication is to highlight the industrial and technological capabilities of the Spanish business sector that contributes to the development of national defense and the projection of its strategic capabilities abroad.

This catalog, distributed among international organizations such as NATO, the European Defense Agency (EDA), OCCAR, and other defense ministries, is a key tool for promoting industrial cooperation, identifying strategic partners, and facilitating the participation of Spanish companies in international tenders and collaborative projects. Through its thematic and technical structure, it allows key players in the sector to locate specific and reliable solutions for their operational and logistical needs.

Gaptek’s participation in this edition reflects its ongoing work to develop agile, sustainable construction solutions adapted to the requirements of rapid deployment, mobility, and operational efficiency. From aircraft hangar projects to field installations for military use, Gaptek’s value proposition responds to a mission-critical approach in demanding environments.

We make reality your project

In an atmosphere of celebration and recognition, Gaptek commemorated its 15th anniversary during the International Defense and Security Exhibition (FEINDEF 2025), one of the most significant events in the sector in Europe. The occasion marked not only a milestone in the company’s history but also a reaffirmation of its commitment to technological innovation, operational excellence, and close collaboration with the Armed Forces.

Over the past 15 years, Gaptek has evolved into a benchmark in modular and technological solutions for the defense sector, adding value through deployable, efficient, and mission-adapted infrastructures that meet the demands of the 21st century. Its approach is rooted in precision engineering, sustainability, and rapid deployment, consolidating a unique value proposition in the market.

The commemorative event, held at the company’s stand during the fair, was honored by the presence of General Francisco Braco Carbó, Chief of Staff of the Spanish Air and Space Force (JEMA), as well as institutional representatives, high-ranking defense officials, and executives from leading companies in the sector. In a solemn and emotional atmosphere, Gaptek’s President, Tomás Feliu, delivered a speech of gratitude in which he acknowledged the continuous support of the Spanish Air Force, a key partner in the company’s development.

During his address, Tomás Feliu highlighted:

“It is a source of pride for us to have had the trust of the Spanish Air Force from the very beginning. Their involvement has been essential for our solutions to reach the level of performance required in real operations. Today, more than ever, we reaffirm our commitment to defense and security.”

One of the most symbolic moments of the ceremony was the toast with the JEMA, which underscored the strong relationship between Gaptek and the Armed Forces. This gesture reflected not only institutional cooperation but also the tangible impact of Gaptek’s infrastructures in both national and international operations. From aircraft hangars to logistics and command centers, Gaptek’s solutions have played a key role in effectively addressing operational challenges.

We make reality your project

We’re back! We are proud to announce that Gaptek will once again be attending FEINDEF, the leading Defence and Security exhibition in Spain.

This year’s participation is especially meaningful as we celebrate 15 years of collaboration with the Spanish Ministry of Defence, international partners and allied institutions, delivering cutting-edge, efficient, and sustainable modular infrastructure solutions.

📌 We look forward to welcoming you at our booth:
📍 Hall 10 | Stand C23

Come and discover our latest developments in hangars, shelters, logistics centres and more.

See you at FEINDEF!

We make reality your project