Transform Airplane Hanger With Epoxy Floors In Atlanta

When it comes to transforming large industrial spaces, especially airplane hangars, the flooring choice is crucial. Not only does it need to be durable and long-lasting, but it also has to look good and meet specific functional requirements. Recently, Pure Epoxy Coatings took on the challenge of revamping an 8000 square foot airplane hangar in Newnan, Georgia. This article dives deep into the journey of flooring in Atlanta, from the initial preparation stages to the final touches that made the hangar floor not just functional, but stunning.

Preparation: Setting the Foundation

Grinding the Floor

When dealing with vast industrial spaces like an airplane hangar, preparation is key. Amar mentions in the podcast that he and Hank just finished grinding 3500 square feet of the hangar floor. This crucial step involves using industrial grinders to remove old coatings and ensure the surface is pristine and ready for new treatments.

Grinding not only cleans the floor but also helps in achieving the optimal surface for epoxy adherence. This preparation step ensures longevity and the impeccable finish of the epoxy flooring system, preventing future peeling or chipping.

Cleaning and Repairing

Once the grinding process is complete, the next step is thorough cleaning. Any dust, debris, or oil stains must be removed to ensure the epoxy adheres properly. Additionally, any cracks or imperfections in the concrete need to be repaired. This meticulous preparation sets the stage for a flawless epoxy application.

The Epoxy Flake System: Adding Strength and Aesthetic

Base Coat Application

The next phase discussed was installing an epoxy flake system with a partial broadcast. Epoxy flakes are small chips that create a unique pattern and add an extra layer of durability to the flooring. Beyond aesthetics, these flakes provide functional benefits by enhancing the surface texture, thus increasing slip resistance.

Amar highlights how they applied the base coat of epoxy and then broadcasted partial flakes over it. This technique allows for better bond and coverage, ensuring that the floor is not only strong but visually appealing. It’s essential to get the right distribution of flakes to achieve the desired look and durability.

Flake Broadcasting

Broadcasting the flakes is a critical step that requires skill and precision. The goal is to achieve a uniform distribution, creating a consistent pattern that enhances both the appearance and the durability of the floor. Amar and Hank’s expertise in this process ensures that the flakes are evenly spread, avoiding clumps or bare spots.

The Polyaspartic Top Coat: Sealing the Deal

Benefits of Polyaspartic Coatings

Once the flakes are set, it’s time to seal the floor with a topcoat. In this project, Amar and his team used a polyaspartic topcoat, an advanced alternative to traditional epoxy. Polyaspartic coatings cure faster, are more UV resistant, and provide greater durability.

However, the team didn’t just stop there; they went a step further by incorporating Sparta Grip into the top coat. This addition plays a critical role in modifying the final finish. Sparta Grip helps matte out the floor, reducing the reflective glare of lights—an important consideration in an airplane hangar where high-intensity lighting can cause significant reflections.

Application Process

Applying the polyaspartic topcoat is a meticulous process. The team must ensure even coverage and proper curing times. The inclusion of Sparta Grip requires careful mixing and application to achieve the desired matte finish. This step is crucial for both the longevity and the functionality of the floor.

Meeting Client Needs: Functional and Aesthetic Balance

Addressing Reflectivity Concerns

One of the key concerns from their client was the reflectivity of the floor. Too much shine can be a detriment in functional spaces like hangars. This is where the expertise of Amar’s team comes into play. By using Sparta Grip, they successfully created a floor that not only looks clean and polished but also minimized glare, thus making it more functional for daily operations in the hangar.

Achieving the Perfect Balance

Balancing aesthetics with functionality is no small feat. Amar and Hank’s attention to detail ensures that the floor not only meets the client’s practical needs but also enhances the overall look of the hangar. The result is a floor that is as beautiful as it is durable.

Challenges Faced and Overcome

Scale and Weather Conditions

No project comes without its challenges, and working on such a large scale presents its unique set of issues. The team needed to ensure that each phase was meticulously executed. Weather conditions, curing times, and the sheer scale of the project required precise planning and flawless execution.

Maintaining Consistency

Maintaining a consistent flake distribution and achieving the right texture with the top coat are other challenges that were effectively managed by Amar and his team. Their expertise and experience in the field are evident in the final product—an airplane hangar floor that promises longevity and functionality.