Welsh aircraft maintenance specialist Caerdav has begun work on a new composites and paint workshop at its St Athan base in South Wales, with the facility expected to open in early 2027 and create additional employment opportunities in the local area.
The development forms part of Caerdav’s long-term growth strategy and will increase its capacity to provide specialist aircraft maintenance support, helping customers reduce costs, minimise aircraft downtime and extend the service life of components.
The project will see the refurbishment of Hangar 64, an unused building adjacent to the company’s Twin Peaks hangars. The transformation will include a new mezzanine office level and 4,300 sq ft of additional workshop space, incorporating dedicated sanding and clean rooms alongside a large paint spray booth.
The spray booth will be designed to accommodate either a single larger job or two smaller projects, giving Caerdav greater flexibility when supporting aircraft maintenance programmes and third-party customers.
Specialist repairs and additional capacity
The new workshop will bring together a dedicated team of composite technicians, mechanics and trainees, providing specialist repair capabilities covering fibreglass, carbon fibre and metal-to-metal bonded structures.
These services will complement the expanded paint facilities, which will also support the refinishing of smaller aircraft components.
By increasing its in-house back-shop capacity, Caerdav aims to offer customers a wider range of services alongside its existing aircraft maintenance operations. The additional capability is expected to support work on aircraft already undergoing maintenance at St Athan, as well as projects for external customers seeking specialist repair and paint services.
Alan Steer, Caerdav’s Base Maintenance Manager, said the development represented another step forward for the business.
“We’re excited to get this project off the ground as it’s another indication of how the business is moving forwards. The additional workshop capacity will allow us to deliver a wider range of services to customers with aircraft in the hangars and also third parties looking for support.”
New opportunities for South Wales
The expansion will also create opportunities for people looking to develop careers in the aviation maintenance sector.
Caerdav expects to recruit additional staff to support the new facility, with the company highlighting the potential for engineers, technicians and mechanics from other industries to transfer their skills into aviation.
Steer said the company was looking for people with the right aptitude and mindset, rather than restricting recruitment to candidates with previous aviation experience.
The approach could open the door for skilled workers from manufacturing, engineering and other technical sectors to enter the aircraft maintenance industry, alongside opportunities for new trainees.
The workshop is the latest development in Caerdav’s investment in its St Athan operations. It follows the opening of a fourth maintenance line at the beginning of 2026, further expanding the company’s capacity to support aircraft maintenance programmes.
With the composites and paint workshop scheduled to open in early 2027, Caerdav is continuing to develop the specialist services available at its South Wales base, strengthening its ability to support both existing maintenance customers and third-party operators.
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