Aircraft Hangar Flooring
Constant Aviation Maintenance Facility – Cleveland
- Industries: Aviation
- Services: Concrete Surface Preparation, Urethane Concrete
Industrial Flooring For Aviation Facilities
When Constant Aviation, a leading aircraft maintenance and repair organization serving Flexjet and other private aviation operators at Cleveland Hopkins International Airport, needed to replace failing flooring in their 15,000 SF maintenance hangar, they faced a critical challenge: complete removal and replacement of deteriorating coatings while maintaining operational capability in a high-traffic environment where aircraft maintenance, heavy equipment, and dropped tools create extreme floor stress daily.
The Challenge
The existing hangar floor coatings were failing catastrophically; extensive cracking, delamination, and coating breakdown had created safety hazards and an unprofessional appearance that didn’t reflect Constant Aviation’s reputation for precision maintenance services. The deterioration was so severe that the entire coating system required complete removal down to bare concrete before any new flooring could be installed.
Operational Requirements
The flooring system needed to support the operational needs of an aviation hangar, including:
- Resist hydraulic fluid and aviation fuel spills.
- Support the concentrated wheel loads of aircraft and ground support equipment.
- Needs to maintain a clean, professional appearance that instills client confidence.
- Bright enough to improve lighting conditions for detailed maintenance work.
- Must provide slip resistance for safety around aircraft.
Hardig's Approach
The new, high-performance flooring system was engineered for maximum durability, combining four distinct layers over the 15,000 SF hangar:
1/8" Urethane Slurry Base Layer
This substantial foundation provided critical impact resistance, accommodated moisture vapor, leveled minor surface irregularities, and offered flexibility to prevent coating failure from substrate movement.
Precision Surface Flattening
A complete grinding operation was performed on the cured slurry to remove trowel marks and ensure a perfectly smooth, level substrate for optimal coating adhesion.
Dual-Coat 100% Solids Epoxy System
Two dense, zero-VOC epoxy grout coats were applied for maximum film build, superior chemical resistance, and to create the foundation for the aggregate texture.
High-Wear Urethane Topcoat with Custom Textured Aggregate
The final finish delivered protection against hydraulic fluids, Skydrol, and jet fuel, high impact resistance, safe slip resistance, and improved light reflectivity.
The completed system measured approximately ten times the thickness of the original coating, permanently concealing all substrate damage beneath a seamless, monolithic surface.
The Results
The project delivered a complete transformation for the 15,000 SF hangar floor.
- The failing coating was eliminated and replaced with a multi-layer urethane concrete system that is 10 times thicker.
- The new system provides superior durability and exceptional impact resistance.
- Previous moisture vapor transmission issues were successfully resolved without delamination.
- The bright, high-reflectivity finish dramatically enhanced the facility's lighting and professional appearance.
- The entire project was completed on schedule (within the 3-4 week timeline).
Project Specifications
- Industry: Aviation/Aircraft Maintenance
- Client: Constant Aviation (Flexjet Maintenance Provider)
- Location: Cleveland Hopkins International Airport, Cleveland, Ohio
- Total Square Footage: 15,000 SF
- Facility Type: Airline Maintenance Hangar
- Project Timeline: 3-4 weeks
- Solution Provided: Urethane Concrete High Wear System
- Systems Installed: Complete coating removal, crack treatment, concrete spall repair, 1/8" urethane slurry base, surface grinding, dual-coat 100% solids epoxy, high-wear urethane topcoat with custom textured aggregate
- Special Requirements: Moisture mitigation, impact resistance, chemical resistance (aviation fluids), aesthetically pleasing bright finish, minimal operational disruption
- Performance Standards: Impact resistance, abrasion resistance, chemical resistance, slip resistance, light reflectivity, seamless appearance
- System Thickness: 10x original coating thickness
Ready to Upgrade Your Aviation Facility Flooring?
Planning a hangar floor replacement, FBO facility upgrade, or aviation maintenance center flooring project? Hardig’s urethane concrete high-wear systems are engineered to withstand the extreme demands of aircraft operations while delivering the professional appearance your facility deserves.