Right arrow Aerospace Manufacturing Flooring

Flooring Solutions for
Aerospace Manufacturing Facilities

Q: What types of flooring are suitable for aerospace manufacturing and hangar areas?

Aerospace facilities usually rely on a designed concrete slab as the structural base, with different surface systems applied according to use. Assembly halls and hangars often make use of resurfacing systems that control levels around rails, pits and anchor points, while logistics and storage areas may use polished concrete for clear markings and straightforward cleaning.

Q: Can you design floors to cope with heavy jacks, docking systems and access platforms?

Yes. Floor design for aerospace sites specifically considers concentrated loads from stands, jacks and docking equipment. Slab thickness, reinforcement and surface details are chosen so support feet are carried by stable concrete rather than weak edges, helping maintain alignment and reduce movement as loads are applied.

Q: How are fuel, oil and hydraulic fluid spills handled at floor level?

Spill management is addressed at the design stage by reviewing likely spill locations, drainage routes and cleaning routines. Falls can be adjusted so fluids move towards collection points, and suitable protective resurfacing can be installed to provide dense, easy-to-clean finishes that support regular washing and housekeeping checks.

Q: Is it possible to refurbish floors while assembly bays or hangars remain in use?

In many cases floors can be refurbished in phases so parts of the facility remain operational. Bays or sections are taken out of service in turn, with clear segregation between work zones and live areas, and completed sections are cleaned and handed back before aircraft or tooling return.

Q: Can new floors help with FOD control and visual inspections?

Improved flooring can significantly assist FOD control by removing rough patches and deep cracks where debris might lodge, and by providing a cleaner background for visual inspections. Suitable surface finishes and line marking schemes help debris stand out and make housekeeping checks more effective.

Q: How long will an aerospace manufacturing flooring project typically take?

Project duration depends on the size of the area, existing slab condition and the need to keep parts of the site running. Smaller zones may be completed within a maintenance window, while larger halls or hangars are often delivered in phases aligned with build programmes and outage periods.

Warehouse Flooring Solutions delivers structural concrete slab installation, mechanically polished concrete surfaces and industrial concrete refurbishment systems for aerospace manufacturing and MRO sites across the UK. Floors are configured around assembly bays, jig lines, component stores and hangar spaces so tooling, aircraft sections and support vehicles can move with confidence.

20 +

Years
Experience in Aerospace Production Flooring

Aerospace manufacturing environments mix precision tooling with large components, suspended structures and specialist vehicles. We install and upgrade floors that support heavy stands and docking systems, help manage fluids and housekeeping, and work in harmony with FOD control, quality standards and customer audit expectations from assembly hall to final completion bay.

Our Expertise

Flooring Needs in Aerospace Manufacturing Facilities

Aerospace sites typically include structural assembly lines, wing and fuselage jigs, composite lay-up rooms, paint preparation areas, test bays, component stores and hangars or MRO docks. The floor must carry concentrated loads from jacks, trestles and access platforms while remaining smooth enough for tugs, dollies and palletised materials to move without jolts. Surfaces must be straightforward to inspect for debris, cope with occasional fluid leaks and integrate with earthing points, pits, rails and service trenches.

Many facilities use high-performance industrial slabs beneath assembly and docking areas, refined with specialist resurfacing systems to control levels around rails, pits and service covers. In logistics corridors and goods-in or despatch zones, polished concrete flooring is common, mirroring the approach used in logistics hubs and general manufacturing plants where clear markings and low dust surfaces support everyday operations.

Need for flat, consistent surfaces under jigs, docking structures and moveable tooling.
Capacity to support tugs, dollies, scissor lifts and MEWPs without progressive damage.
Control of hydraulic fluid, fuel and coolant spills so they can be contained and cleaned efficiently.
Integration with floor rails, pits, anchor points and buried services without creating trip hazards.
Support for FOD control and housekeeping routines, with surfaces that make debris easy to see.

Flooring Problems in Aerospace Manufacturing & MRO Environments

When floors in aerospace facilities begin to deteriorate, the consequences reach far beyond appearance. Localised defects can affect tooling stability, disrupt vehicle movement and complicate FOD inspections, with issues often highlighted quickly by safety teams, customers or regulatory audits.

Settlement beneath jigs or docking systems affecting alignment and access positions

Damaged slab joints causing noticeable jolts for tugs, dollies and maintenance platforms

Surface breaking away around anchor points, rails or service covers

Areas of oil, fuel or hydraulic staining that are increasingly difficult to clean effectively

Low spots where wash water or fluids collect in hangars or assembly bays

Patch repairs and older coatings that flake, creating potential foreign object debris

Right arrow Our Process

How We Upgrade Floors in Aerospace Manufacturing Facilities

STEP 1

Technical Survey and
Operational Review

We walk the facility with your engineering, production and safety teams, reviewing assembly layouts, hangar bays, access platforms and vehicle routes. We record existing defects, drainage performance and any known issues with tooling stability or FOD control. Consideration is given to live aircraft movements, weight limits, and future plans for new jigs or expanded MRO capacity.

Double arrows STEP 2

Floor Design,
Load & Surface Specification

We prepare a scheme that may combine new ground-bearing slab construction in selected bays, concrete resurfacing and levelling systems around jigs and service trenches, and polished concrete finishes in logistics aisles. Joint details, slab thickness, reinforcement and surface textures are chosen to suit aircraft components, docking structures and supporting equipment, drawing on approaches used successfully in electronics manufacturing environments and other precision industries.

Double arrows STEP 3

Installation,
Phasing and Handover

Works are scheduled around build programmes, maintenance slots and hangar usage. We segregate the work zone, manage dust, and coordinate with your operations team so aircraft, tooling and vehicles remain safely separated. Defective concrete is removed, slabs and surfaces are rebuilt as required, and each area is handed back ready for your cleaning, FOD checks and operational sign-off before aircraft or production equipment return.

BS 8204

Floors are designed and finished in line with BS 8204, helping to provide the surface regularity needed for jigs, docking systems and smooth vehicle operation within assembly halls and hangars.

BS EN 206

Concrete works follow BS EN 206 guidance for mix design and curing, supporting consistent performance under heavy point loads from stands, jacks, racking and specialist handling equipment.

CSCS Certified

Our operatives hold CSCS cards and are accustomed to working within controlled access zones, strict safety rules and permit systems commonly applied in aerospace and MRO facilities.

SMAS Worksafe

SMAS Worksafe accreditation confirms compliance with SSIP schemes, supporting structured safety management on flooring projects across complex aerospace manufacturing sites.

Right arrow FAQ

Aerospace Manufacturing Flooring
Common Questions

What types of flooring are suitable for aerospace manufacturing and hangar areas?

Aerospace sites generally use a designed concrete slab as the base, with surface systems chosen for each zone. Assembly halls and hangars may use concrete resurfacing systems to control levels around rails, pits and anchor points, while logistics routes and stores often benefit from polished concrete floors. The combination is selected to support heavy stands, aircraft movements, tugs and pallet handling without compromising housekeeping standards or FOD checks.

Can you design floors to cope with heavy jacks, docking systems and access platforms?

Yes. Concentrated loads from stands, jacks and docking structures are a key part of the design process. We consider the positions, load paths and expected usage patterns, then specify slab thickness and reinforcement accordingly. Surface treatments and joint details are chosen so support feet sit on stable, well-formed areas rather than fragile edges, helping maintain alignment and reducing movement as equipment is loaded and unloaded across the life of the facility.

How are fuel, oil and hydraulic fluid spills handled at floor level?

During design we review where fluids are most likely to be present and how they will be cleaned. Falls and drainage can be adjusted so that liquids move towards defined collection points rather than remaining in low spots. Suitable protective resurfacing systems can be installed to provide a dense, easy-to-clean surface that stands up to regular cleaning regimes. This helps reduce staining, supports housekeeping records and makes it simpler to show effective management of spills during audits or customer visits.

Is it possible to refurbish floors while assembly bays or hangars remain in use?

In many cases, yes. Projects are typically phased so that specific bays, sections of a hangar or parts of a line are released in turn. We work with your planning and operations teams to coordinate aircraft movements, tooling relocation and access routes. Work zones are segregated and clearly marked, and completed areas are cleaned and handed back before being returned to normal use. This phased approach allows production and maintenance activities to continue alongside the flooring upgrade programme.

Can new floors help with FOD control and visual inspections?

Yes. A key benefit of improved flooring is easier FOD detection and tidier presentation. By removing rough patches, failed coatings and deep cracks, the floor is less likely to trap small items. Finishes such as polished concrete or well-chosen resurfacing systems provide a cleaner background so debris stands out. Line markings, colour zones and clear transitions between working and walking areas can also be incorporated, supporting routine sweeps and formal housekeeping inspections.

How long will an aerospace manufacturing flooring project typically take?

Timescales depend on the area involved, slab condition, chosen system and how much of the site must remain operational. Smaller bays can sometimes be completed within a maintenance window, while large hangars or assembly halls may be tackled in several phases. Early surveys allow us to outline realistic durations and sequencing, and we then work with your project and operations teams to align the programme with outage periods, aircraft slots and other works on site.

Flooring Solutions for
Aerospace Manufacturing Facilities

Flooring Needs in Aerospace Manufacturing Facilities

Flooring Problems in Aerospace Manufacturing & MRO Environments