Designing Chemical-Resistant Flooring for an Aircraft Hangar

The Challenge: Protecting a Heathrow Aircraft Hangar from Wear and Chemical Spills

Virgin Airlines’ aircraft hangar at Heathrow Airport required a flooring solution capable of withstanding heavy operational demands while maintaining a clean, professional appearance. The floor needed to resist constant wear, frequent chemical spillages and exposure to aggressive hydraulic fluids such as Skydrol.

In addition to durability, the client wanted a light-coloured, high-gloss finish that would reflect light and enhance visibility across the 4,000 square metre hangar. Brightening the space was essential to improve working conditions, efficiency and overall visual impact in a busy aviation maintenance environment.

The challenge was to deliver a flooring system that combined long-term performance, chemical resistance and aesthetic appeal in a high-traffic aircraft hangar setting.

The Solution: Installing a High-Performance Resin Flooring System for Aviation Use

To achieve a durable and visually striking finish, the proven Resutile ST floor coating system was selected for the project. Specialist resin flooring contractor Datum Flooring prepared the concrete substrate by shot-blasting under vacuum to achieve a Concrete Surface Profile (CSP) 3. This ensured an excellent mechanical key for long-term adhesion and performance.

A primer coat of Resuflor WB was then applied. This penetrated the concrete, sealed the surface and created a sound base to ensure an even finish for the subsequent top coats.

The system was completed with two roller-applied coats of Resutile ST Colour in Light Grey. This created a seamless, high-gloss surface designed to withstand the demanding conditions of an aircraft hangar.

Resutile ST delivers a tough, durable finish with a degree of flexibility, helping it resist wear from heavy equipment and aircraft movement. The product is fully light stable, offering excellent protection against UV degradation. It also provides strong resistance to aggressive chemicals commonly used in aviation environments, including Skydrol and Hyjet.

The result was a smooth, bright and resilient floor that met both the functional and aesthetic requirements of the hangar.

The Results: Long-Term Performance in a High-Traffic Aviation Hangar

After five years of service, the Resutile ST flooring system continues to perform exceptionally well. The coating withstands the constant movement of aircraft and pushback tractors while resisting staining from hydraulic fluid, oil spillages and hot tyre pick-up.

Virgin Airlines’ aircraft fleet is regularly moved in and out of the hangar, placing significant stress on the floor. Despite this heavy use, the Resutile ST system maintains its integrity, appearance and chemical resistance, proving to be a solution worthy of a world-class charter organisation.

Resutile ST has been used in aviation hangars worldwide for over three decades, providing outstanding UV stability and chemical resistance for demanding aerospace environments. Most installations, including this project, use the Light Grey colour, which maximises light reflection and helps to brighten large operational spaces.

The completed floor delivers long-lasting protection, improved visibility and a professional finish, supporting efficient aircraft maintenance operations at one of the UK’s busiest airports.