Project Overview
Roe Painting was selected to install a high-performance concrete coating system for a newly constructed 20,000 square foot private aircraft hangar at the Boise Airport. While the client remains private, the scope and expectation of the project were anything but small.
The hangar was built to replace an existing space that was less than half the size. With this expansion came higher standards for appearance, durability, and long-term value. The client wanted a floor that would look exceptional, remain easy to maintain, and stand up to aircraft traffic, equipment movement, and chemical exposure over time.
This project became one of the largest concrete coating installations Roe Painting has completed and one of the most visually striking.
The Challenge
Several factors made this project complex:
Scale and Layout
The hangar floor was a single, wide-open space with no natural breakpoints. At roughly 20,000 square feet, the size alone required careful planning, sequencing, and execution to maintain consistency across the entire surface.
Environmental Conditions
The main coating installation took place in October and November of 2025, as temperatures dropped and weather conditions became less predictable. Cooler temperatures slowed cure times, and the hangar doors had to remain open at times to complete work on door tracks, introducing wind and moisture concerns.
Long-Term Performance Expectations
Because of the size and investment, failure was not an option. Moisture vapor, which fluctuates seasonally, poses a risk to adhesion and long-term performance if not properly addressed.
Aesthetic Expectations
The client prioritized a bright, clean, reflective finish that would elevate the space visually while also improving visibility and ease of inspection.
The Solution
Roe Painting approached the project with a consultative mindset, asking detailed questions about how the hangar would be used, what equipment would be present, and what performance characteristics mattered most. Based on those discussions, the team designed a system that balanced performance, appearance, and long-term value.
Evaluating the Right Coating System for the Space
As part of the planning process, Roe Painting evaluated multiple coating systems, including urethane cement, which is commonly used in environments with heavy mechanical work, frequent impact, or extreme abuse.
This hangar, however, was designed primarily for boarding passengers and parking the aircraft, not ongoing mechanical repair. While light maintenance may occur, the performance demands did not justify the added cost of a urethane cement system. Instead, a high-build epoxy system with a polyurethane topcoat provided the durability, chemical resistance, and clean, reflective finish the client wanted.
The result was a coating solution that made sense functionally and delivered long-term value without unnecessary overengineering.
Surface Preparation
Instead of traditional grinding, Roe Painting selected shot blasting to prepare the slab. This method uses steel shot propelled at a high velocity to open the concrete surface and expose the absorbent layer beneath the surface. Shot blasting is ideal for thicker, high-build coating systems and ensures proper adhesion across the entire floor.
"Moisture vapor primer is an insurance policy. Moisture vapor drive changes throughout the year, and if you don't account for, it can cause a coating to fail."
Moisture Vapor Protection
A moisture vapor barrier primer was installed as a first coat. This step acts as an insurance policy, protecting the system from seasonal moisture vapor pressure passing through the concrete that can cause coating failures if left unmanaged.
Coating System
The final system consisted of three layers:
- Moisture Vapor Barrier Primer
- 100% Solids Self-Leveling Epoxy Basecoat, tinted white
- Polyurethane Topcoat, for added durability, UV protection, and chemical resistance.
The epoxy was applied in controlled sections, allowing the self-leveling material to flow evenly and create a uniform, mirror-smooth finish.
Joint Treatment and Safety Features
Concrete control joints were filled by hand using epoxy thickened with additives, eliminating visual interruptions and creating a seamless appearance across the floor. In total, approximately 1,500 linear feet of joints were addressed.
A 5-foot-wide safety yellow walkway was added along three sides of the hangar with texture to improve visibility and traction without compromising the clean aesthetic of the main floor.
The Results
The finished floor delivered exactly what the client was looking for:
- Bright, Reflective Appearance
The white epoxy finish dramatically brightened the hangar, making the space feel larger and more illuminated even when the lights are off. - Seamless, Easy-to-Clean Surface
The smooth, joint-filled floor simplifies cleaning and inspection while reducing dust and debris accumulation. - Chemical and Impact Resistance
The epoxy and polyurethane system protects against fuel, oil, and other chemicals commonly found in aviation environments. - Long-Term Value
With proper maintenance, the floor is expected to perform for 10 to 15 years, with the option to refresh only the topcoat in the future rather than replacing the entire system.
Client reaction was overwhelmingly positive. Ownership praised the finished floor, and even pilots commented on the quality and appearance of the space.
Why This Project Matters
This aircraft hangar illustrates an important truth about concrete coatings: there is no one-size-fits-all solution.
The success of this project came from asking the right questions, understanding how the space would be used, and selecting a system that aligned with performance needs rather than defaulting to the cheapest or most common option.
For industrial facilities, warehouses, and commercial developments, this project demonstrates how the right preparation, materials, and experience can turn a concrete floor into a durable asset that enhances both function and appearance.
To discuss your options or schedule a complimentary consultation for your space, just request a quote and our team will connect you with a concrete coatings or painting professional.
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