Airplane hangars require flooring that can withstand heavy wear, impact, and chemical exposure. Engines, large parts, hoists, and jacks dragged across the floor can quickly degrade bare concrete. Engine components, dropped tools, sharp objects, and normal hangar operations can damage the substrate. Aircraft maintenance operations often involve specialized chemicals, oils, and fuels, which can permeate and deteriorate uncoated concrete. For these reasons, forward-thinking fixed-base operators (FBOs) understand the value of advanced hangar floor coating systems.

Engineered for superior chemical resistance and slip protection, resinous floor coating systems provide a resilient foundation that meets the stringent demands of aviation facilities. Whether shielding concrete from chemical attack or creating a smooth, uniform surface for aircraft movement, high-performance coatings enhance safety, efficiency, and the long-term durability of hangar environments.

Restoring a degraded hangar

The recent repair work at Perot Field Airport in Fort Worth, Texas, demonstrated the value of floor coating systems. Owned by the City of Fort Worth and managed by privately held Alliance Aviation Services (Alliance), Perot Field offers state-of-the-art infrastructure and features an award-winning Federal Aviation Administration (FAA) air traffic control tower. The facility includes six hangars with more than 18,580 m² (200,000 sf).

One hangar was dedicated to maintenance, which Alliance planned to open to privately owned general-aviation aircraft. However, the hangar’s concrete was damaged, cracked, and eroded after years of service, requiring repairs before it could be fully utilized.

A manufacturer of high-performance epoxy, urethane-based floor coating products, and concrete repair systems for commercial, institutional, and industrial floors was brought into the project. The company was chosen for its experience in providing coating systems engineered for aircraft hangars and other environments where durability, safety, and efficiency are critical.

With high-capacity manufacturing plants across the country, the manufacturer could deliver materials on schedule despite supply chain challenges. This was essential, given Alliance’s tight timeline. Because aircraft would need to remain outdoors during the renovation, completing the project quickly was a priority, especially with an upcoming hangar inauguration event and guests.

The Process

The manufacturer partnered with CNH Decorative Concrete, LLC (CNH), an Arlington, Texas-based company. Led by Pablo Canela, the CNH team recognized that coating systems would be essential to creating a safe, durable, and visually appealing space where Alliance’s clients could confidently house and service their aircraft.

The 4,645 m² (50,000 sf) concrete floor was first shot-blasted to prepare the surface for coating adhesion. By propelling steel beads at high velocity, the process removed contaminants and created the necessary profile for bonding the multilayer system. CNH then applied an epoxy moisture-vapor barrier, serving as a single-coat primer for the concrete. The low-viscosity formulation enhances substrate penetration and adhesion while effectively blocking moisture drive—critical for long-term performance.

“I knew the manufacturer’s innovative and high-performance floor coating systems would be a perfect solution for Alliance. Since the concrete didn’t have an existing coating, this will make a substantial difference in long-term maintenance of the hangar,” said Canela.

Next, a two-component epoxy primer and coating were applied further to strengthen the flooring against chemical exposure and heavy traffic. The system was topped with a fast-curing polyaspartic coating to deliver a robust finish with exceptional resistance to impact, abrasion, and chemicals. The polyaspartic layer also resists UV-induced color fading and discoloration, maintaining a clean and bright appearance over time.

Results

The finished system not only elevated the hangar’s aesthetic appeal but also significantly improved the structural integrity of the concrete surface. The comprehensive, multi-layer approach provides long-term resilience against moisture, chemicals, and heavy usage. It delivers a durable, high-performance flooring solution tailored to the rigorous needs of the aviation industry.

The light-colored, glossy topcoat increases floor reflectivity, improving illumination, visibility, and safety. The smooth, bright surface also makes it easier to locate small, dropped parts and identify spills or fluid leaks from aircraft.

Alliance Aviation is confident that the new floor coating system will withstand the weight and traffic of aircraft and the daily challenges of maintenance operations.

Omar Argüelles is the central regional manager with Crown Polymers and may be reached at omar@crownpolymers.com. Crown Polymers is a leading manufacturer with over 30 years of expertise in high-performance industrial flooring coatings, decorative floors, and concrete repair systems. For more information, visit crownpolymers.com.