Concrete repairs threatened to ground aircraft and empty out active hangars. TuffWrap kept planes in place and work moving forward.

Repairing hangar floors is rarely a simple job, especially when the hangars are occupied. When a medium-sized airport needed to repair the concrete in several of its rented hangars, it ran into a costly complication: many of those hangars were actively in use, and the repair work would generate a significant amount of hazardous dust. Without a way to contain it, the airport would have to coordinate with renters to relocate a number of aircraft, an undertaking that would strain relationships with tenants and throw off schedules across the facility.

The Challenge: Repair Hangar Floors Without Relocating Aircraft

Concrete work in an occupied hangar isn’t just disruptive, it’s a hazard to aircraft, equipment, and anyone working nearby. The airport needed a solution that could:

  • Contain hazardous dust generated by concrete repair work
  • Allow aircraft to remain safely in place inside occupied hangars
  • Give crew and construction vehicles reliable access to and from the worksite
  • Avoid the disruption and cost of relocating tenants’ planes

The Solution: C.O.R.E. Frameless Walls® with Pocket Doors®

The airport reached out to TuffWrap, and the team’s answer was a series of C.O.R.E. Frameless Walls®. The walls were used to bisect the hangars, sealing off the areas under repair from the rest of the space. That meant aircraft could stay safely in the same hangar throughout construction, with hazardous dust contained on the work side of the wall.

Because the project still required regular movement of crew and construction vehicles, TuffWrap built in its signature Pocket Doors®, giving the work crew easy access to and from the worksite without breaking the seal protecting the aircraft.

The Result: Aircraft Stayed Put, Repairs Stayed on Schedule

Once the walls were in place, the airport had exactly what it needed: concrete repairs moving forward on one side of the wall, and aircraft sitting safely undisturbed on the other. There was no need to relocate planes or shuffle tenants around to accommodate the work.

The airport was thrilled with the outcome. Instead of diverting resources to coordinate construction logistics and juggle aircraft, they were able to maintain their regular schedule without interruption.

Why This Matters for Airports and Hangar Facilities

Concrete repairs and facility maintenance are inevitable at any airport, but they don’t have to come at the cost of tenant relationships or operational disruption. TuffWrap’s C.O.R.E. Frameless Walls®, paired with Pocket Doors® for job-site access, give airports a way to complete critical repairs while keeping aircraft exactly where they belong.