Installing Aircraft Hangar Flooring That Combines Durability and High-Gloss Aesthetics

The Challenge: Delivering Durable, Chemical-Resistant and Visually Striking Hangar Flooring

When Best Jets relocated to Holman Field in St. Paul, Minnesota, the private aircraft charter company constructed two new hangars totalling 20,000 square feet. The goal was clear: install a flooring system that could balance demanding performance requirements with a high-end, visually appealing finish.

The floors needed to withstand constant aircraft movement, including planes and pushback tractors, while resisting hydraulic fluid, oil spills and hot tyre pickup. At the same time, the client wanted a bright, high-gloss surface that would enhance the overall appearance of the hangars and reflect the premium nature of its fleet.

Confidence in the system and supplier was also critical to project success. As Eric Tranberg, co-owner of HTF Solutions, explained:

“By choosing Sherwin-Williams, we knew everything would go smoothly with delivery and application of the product and, if there were issues, they would be behind us.”

Compounding the challenge, the project faced difficult site conditions. Rainy weather delayed the start of installation, and wind-driven rain entered one hangar during application, requiring partial rework. Despite these setbacks, the team needed to maintain project timelines and deliver a flawless finish across both hangars.

The Solution: Custom Multi-Coat Epoxy Hangar Flooring System for Performance and Finish

To achieve both durability and aesthetics, Sherwin-Williams adapted its traditional hangar flooring system to include a heavy body coat designed to level and conceal imperfections in the concrete substrate.

The installation team, led by HTF Solutions in collaboration with Sherwin-Williams Protective & Marine Coatings and general contractor R.J. Ryan Construction, Inc., began by shot-blasting the concrete to achieve a Concrete Surface Profile (CSP) 3. This ensured optimal adhesion for the subsequent coatings.

To seal the slab and prevent outgassing, Resuprime™ ST—a high-solids, low-viscosity binder resin—was applied at 250 microns. Its ability to penetrate deeply into the concrete helped stabilise the substrate, while a thickening agent was added in certain areas to smooth poorly finished edges.

Next, a heavy body coat of Resuflor™ High-Performance Epoxy was applied at 2 mm. This two-component, recoatable epoxy was used to level the surface and fill divots, creating a more uniform base capable of withstanding heavy aircraft traffic.

The system was completed with Resutile™ topcoats, applied in two layers at 40 microns each and cross-rolled for complete coverage. This high-performance topcoat delivers a durable, high-gloss finish with excellent resistance to wear, UV exposure and aggressive chemicals.

Tranberg highlighted the importance of the second topcoat in achieving the final finish:
“After the first topcoat, it looked good, but still had some minor imperfections. The second coat made it look stunning. Because we were applying each coat at low mils, the second coat really helped to bring it all together. We will use two topcoats for other hangars, as it truly enhanced aesthetics and made the floor a beautiful surface.”

Despite weather-related disruptions—including wind-driven rain entering one hangar—the team successfully completed the installation on schedule, supported by reliable product supply from a nearby Sherwin-Williams store.

The Results: High-Gloss, Long-Lasting Hangar Floors Built for Aircraft Operations

The completed flooring system delivered both the performance and appearance Best Jets required. The seamless epoxy surface provides a durable, easy-to-maintain finish capable of handling the intense demands of aircraft operations.

After a year of service, the floors have demonstrated exceptional resistance to wear, chemical exposure and heavy traffic. In the first few months alone, more than 50 planes were moved in and out of a single hangar, yet the flooring maintained its integrity and appearance.

Michael Victor, Director of Maintenance at Best Jets, noted the results exceeded expectations:

“I thought we would see paint chipping or peeling, or at least some stains. But we haven’t seen any of that so far. We’re not noticing any hot tyre pickup either.”

Today, the hangar floors deliver a sleek, high-gloss finish that enhances lighting and visual appeal while providing long-term durability. The result is a premium flooring system that supports daily operations and reflects the quality of Best Jets’ world-class charter fleet.