In the aviation industry, flooring is more than just a foundation—it’s a frontline defense against chemical exposure, heavy equipment, and strict safety requirements. Hangar floors, in particular, endure extreme challenges: constant contact with aircraft, exposure to harsh substances like jet fuel and hydraulic fluids, and the need to maintain both durability and compliance. If left unprotected, these floors can deteriorate quickly, leading to costly repairs, safety hazards, and regulatory issues.
At CustomCrete, we’ve worked with aviation facilities across the Midwest to design and install aviation industry flooring systems built to withstand chemical abuse while supporting safety and efficiency. Drawing from that experience, this blog breaks down how to protect hangar floors and what materials work best under these demanding conditions.
The Risks Jet Fuel and Hydraulic Fluids Pose to Hangar Floors
Jet fuel and hydraulic fluids are among the most damaging substances for concrete. When spilled, they don’t just stain—they penetrate deep into the slab. Over time, this exposure can:
- Break down the surface of untreated concrete
- Weaken structural integrity
- Create slick, unsafe conditions for staff and equipment
- Generate long-term odors and staining that are nearly impossible to remove
Even small spills, if frequent, can compound the problem. Without the right protective measures, hangar floors can become hazardous and costly liabilities.
Why Concrete Alone Isn’t Enough
Bare concrete, while strong, is naturally porous. This means that without some form of protection, jet fuel and hydraulic fluids will seep into the slab, leading to the issues mentioned above. Simply cleaning up spills isn’t enough, as the damage often occurs beneath the surface where it can’t be seen until it’s too late.
This is why aviation industry flooring solutions almost always involve coatings, sealers, or overlays that add a chemical-resistant barrier to the floor.
Protective Flooring Solutions for Aviation Facilities
Different coating and flooring systems offer varying levels of protection. The right choice depends on the size of your hangar, the level of chemical exposure, and your maintenance priorities.
Epoxy Coatings
Epoxy flooring systems create a seamless, non-porous surface that prevents chemicals from penetrating the concrete. They are highly durable and can be customized with slip resistance and striping for safety zones. However, epoxy can be sensitive to extreme temperature swings, so it’s best suited for controlled environments.
Urethane Cement
For maximum chemical and thermal shock resistance, urethane cement is a top choice. It withstands repeated exposure to jet fuel, hydraulic fluids, and other aggressive substances without breaking down. Its strength and longevity make it ideal for hangars that face continuous heavy-duty use.
Polished Concrete with Sealers
Polished concrete can also be used in hangars if treated with high-quality penetrating sealers. These sealers reduce porosity and provide a protective barrier against spills. While not as chemically resistant as epoxy or urethane cement, polished and sealed concrete offers a balance of durability, aesthetics, and ease of cleaning.
Maintenance Best Practices
No matter which flooring system you choose, consistent maintenance is key to protecting your investment. Best practices include:
- Immediate spill cleanup: Prevents chemical penetration and slip hazards.
- Regular inspections: Spotting cracks, chips, or coating wear early helps avoid bigger repairs.
- Scheduled resealing or recoating: Extends the life of the flooring system by keeping protective barriers intact.
- Proper cleaning agents: Avoid harsh cleaners that could degrade sealants or coatings.
Additional Benefits of Chemical-Resistant Flooring
Beyond protection from jet fuel and hydraulic fluids, high-performance flooring systems also offer:
- Compliance with safety regulations in the aviation industry
- Improved brightness by reflecting light, reducing energy costs
- Slip resistance to safeguard crews and equipment
- A professional, clean appearance that reflects the high standards of aviation facilities
FAQ: Protecting Hangar Floors from Chemical Exposure
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Why do hangar floors need extra protection from jet fuel and hydraulic fluids?
Jet fuel and hydraulic fluids are highly corrosive and can penetrate untreated concrete, leading to staining, surface damage, and even structural breakdown over time. Protective coatings like epoxy or urethane cement create a barrier that prevents these chemicals from seeping into the slab.
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What type of flooring is best for chemical resistance in aviation facilities?
Urethane cement is typically the most reliable option because it provides superior resistance to chemicals and thermal shock. Epoxy coatings also perform well and can be customized for slip resistance and line striping. Polished concrete with high-performance sealers may be used in lighter exposure areas but isn’t as resistant as urethane or epoxy.
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How often should hangar floors be maintained or recoated?
The frequency depends on the type of flooring system and the level of exposure. Epoxy coatings may require recoating every few years in high-use environments, while urethane cement can last much longer with minimal upkeep. Regular inspections and prompt spill cleanup are essential to extend the lifespan of any flooring system.
Conclusion: Invest in Flooring That Protects Your Hangar
Protecting your hangar floors from jet fuel and hydraulic fluids isn’t just about aesthetics—it’s about safety, compliance, and long-term savings. With the right aviation industry flooring system, your facility can prevent damage, reduce downtime, and maintain a professional environment that supports smooth operations.
If you’re exploring flooring upgrades for your aviation facility, consider whether epoxy, urethane cement, or polished concrete with sealers aligns best with your needs. Each offers unique advantages, but all ensure that your floors remain strong, safe, and ready for the demands of modern aviation.
Next, you might find it helpful to read our blog: “Choosing the Right Floor for Your Hangar: Epoxy vs Polished Concrete”.
