Stonhard Floors Provide a "Safe Landing" for Airbus, European Aeronautic Defense and Space Company

Military aircraft manufacturer selects Stonhard for flooring project over five competitors.

Airbus has become one of the world's leading suppliers of military aircraft, satellites and defense electronics, and a notable manufacturer of commercial passenger jets, helicopters, commercial space launchers and missiles.

Airbus’ Aeronautics division contains the ATR unit responsible for craft final assembly and inspection, test flights, certification, and customer deliveries. They specialize in the manufacture of turbo prop aircraft and are the world’s second largest commercial plane constructor. This unit also engineers wing designs and cutting-edge information technology.

When this prestigious division undertook manufacturing A380 super jumbo airplanes, they also faced a new challenge in 'space' -- their existing facilities were not large enough to accommodate the manufacture of A380s, so ATR turned to the Airbus division for help. With 16 development and production sites in Europe, many of them constructed before WWII, Airbus was able to assist by allocating one of their buildings to ATR.

With space acquired, ATR and Airbus now had the task of making that space suitable for manufacturing. Over 50-plus years of demanding wear and lack of maintenance left the concrete substrate in severe disrepair. Stonhard was selected from among five competitors who were each required to install a test patch. Stonhard not only engineered a flooring solution that could completely refurbish the existing substrate, but they surpassed Airbus’ expectations and requirements by providing a floor that would withstand the demands and rigor of an aircraft manufacturing assembly plant and would not impede production.

The project was completed in 11 phases, each beginning with extensive substrate preparation that included crack repair and leveling damaged concrete areas using Stonset TG4, a fastsetting, epoxy-based grout. Blastracs and scarifiers were used to expose the substrate and create a smooth and even surface for the product installation.

The entire area was then covered with Stonclad GS, a troweled mortar base designed to provide durability and long-term protection against impact, abrasion, and heavy-duty traffic. Stonkote GS4, a general service epoxy coating, was applied to provide an impervious, chemical-resistant surface to withstand punishing aircraft fuels and oils. Stonclad’s seamless finish allows easy cleanup of the harshest chemicals and keeps maintenance expenses to a minimum.

This long-term solution eliminates erratic budgets as a result of continuous, costly repairs. Even morale received a serious boost with these dazzling new floors. The final phase of the project involved creating discernible traffic aisles throughout the facility by applying Stonkote GS4 in bright white lines.

The striped traffic aisles were easy to recognize and adhered to safety regulations ensuring a sound work environment. With dedicated cooperation from everyone at Airbus, ART and Stonhard, and with daily on-site project management by the local Stonhard Project Manager, this installation was completed on time and did not interfere with ART’s daily operations. 

The floors went from deteriorated, difficult-to-maintain surfaces to long-wearing, seamless, easy-to-clean, chemical, impact and abrasion-resistant floors. Since the installation, Airbus has found production is more efficient and maintenance is much easier. This long-term solution eliminates erratic budgets as a result of continuous, costly repairs.  Even morale received a serious boost with these dazzling new floors.

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