Aircraft Hangar Floor Coatings
Hangar floors carry aircraft, tugs and ground equipment while resisting fuels, hydraulic fluids and cleaners. Coatings improve cleanability, light reflectance and safety for maintenance work.
Aircraft hangar floor coatings are flooring systems applied to the concrete slabs of hangars used to store, maintain and repair aircraft. Hangar floors are large, often heavily loaded, and exposed to jet fuel, aviation gasoline, hydraulic fluids, lubricants, de-icing fluids, solvents and cleaners. Maintenance crews need bright, clean floors for spotting dropped parts and leaks, and the floor must provide safe footing around aircraft and equipment. Coatings address all of these needs and are a specialized form of concrete floor coatings. Related topics are covered in aerospace coatings.
Performance requirements
Chemical resistance
Hangar floors must resist:
- Jet fuel and aviation gasoline.
- Phosphate ester hydraulic fluids, often known by trade names, which are aggressive toward many coatings and paints.
- Mineral and synthetic hydraulic fluids and oils.
- Glycol de-icing fluids.
- Cleaning solvents and alkaline cleaners.
Phosphate ester fluids deserve special attention. Coatings should be tested or rated for resistance to the specific fluids used (see chemical resistance testing).
Load and abrasion
Aircraft wheels, tugs, jacks, lifts, tool carts and forklifts impose concentrated loads and wear. Turning tires can scuff and lift weak coatings, a problem sometimes called hot tire pickup in other floor uses.
Light reflectance
Light-colored, glossy floors reflect light onto the undersides of aircraft, helping maintenance work and inspection. This is one of the main reasons hangar owners coat floors.
Slip resistance
Fuels and hydraulic fluids create very slippery conditions. Textured finishes in work zones and walkways improve traction (see anti-slip coatings and slip resistance testing).
Static control
Some hangars, particularly those handling electronics or fuel, specify static-dissipative or conductive flooring. Static control requirements are set by the facility and applicable standards.
Fire safety
Hangars are subject to fire codes, including requirements for drainage, foam suppression systems and floor construction. Floor coatings must not interfere with trench drains and fire suppression design, and flammability of floor finishes may be regulated.
Common systems
| System | Characteristics |
|---|---|
| Epoxy coatings | Widely used; good chemical resistance and high-build; often with a urethane topcoat |
| Novolac epoxy coatings | Improved resistance to aggressive chemicals |
| Polyurethane coatings | Aliphatic topcoats for gloss retention, abrasion and fluid resistance |
| Polyaspartic coatings | Fast cure, UV stable, quick return to service |
| Urethane cement flooring | Heavy-duty; thermal shock and chemical resistance |
| Spray polyurea | Fast cure and abrasion resistance; used in some hangars and aprons |
Topcoats with UV stability matter where hangar doors expose floors to sunlight (see aliphatic vs aromatic coatings).
Design details
- Color and markings. Light base colors with safety lines, aircraft parking positions, keep-out zones and equipment paths.
- Textured walkways around aircraft and in wash bays.
- Trench drains. Coatings must terminate cleanly at drain edges and be compatible with drain materials.
- Joints. Large slabs have many joints. Joint fillers and treatment prevent spalling under wheels.
- Tie-down points and grounding points must remain accessible.
Surface preparation
- Degrease thoroughly. Hangar slabs often contain years of fuel and oil contamination.
- Test for contamination and remove oil-soaked concrete where needed.
- Mechanically prepare by shot blasting or grinding (see shot blasting concrete).
- Test moisture (see concrete moisture testing).
- Repair cracks, spalls and joints (see concrete crack repair before coating).
Scheduling
Hangars are often in continuous use. Coating projects may be phased by bay, scheduled during off seasons, or use fast-cure systems to limit downtime. Cure times must be respected before aircraft and heavy equipment return (see coating project scheduling).
Safety during installation
- Remove or protect aircraft and sensitive equipment.
- Ventilate for solvents and isocyanates (see ventilation for coating work).
- Control ignition sources where fuels or flammable coatings are present (see fire and explosion hazards).
- Coordinate with fire protection systems to avoid accidental discharge.
Maintenance
- Clean spills promptly, especially phosphate ester fluids.
- Use cleaners approved by the coating manufacturer.
- Inspect high-traffic and turning areas.
- Recoat topcoats before wear reaches the base coat.
In practice
In practice, hangar floor projects are scheduled around aircraft operations, often in phases so part of the hangar remains usable. The concrete is tested for moisture, prepared and repaired, and the coating system is selected for fluid resistance, light reflectivity and slip resistance. The owner should check the coating against fire code and insurance requirements, including those for foam fire suppression systems and drains.
Key terms
- Hangar floor. A concrete floor in an aircraft hangar exposed to traffic, fluids and maintenance work.
- Hydraulic fluid. Aviation fluids that can attack some coatings.
- Light-reflective floor. A light-colored floor that improves visibility under aircraft.
- Static control. Measures that reduce static electricity in specific work areas.
- Fire suppression. Foam systems in hangars that floors and drains must accommodate.
Frequently asked questions
Why are hangar floors usually white or light gray?
Light floors reflect light upward onto aircraft, improving visibility for maintenance and inspection.
Will any epoxy resist hydraulic fluid?
No. Phosphate ester fluids attack many coatings. Choose products tested for the fluids used.
How long does a hangar floor coating take to install?
It depends on area, system and phasing. Fast-cure systems can reduce downtime.
Related entries
- Aerospace coatings
- Concrete floor coatings
- Floor coating failures
- Chemical resistance testing
- Slip resistance testing (new)
- Concrete crack repair before coating (new)
Educational reference. Coating performance varies by formulation. Always follow the manufacturer’s product data sheet, safety data sheet and your project specification.
