
Soaring in Sugarland, Texas with Fogle Aviation
Flowcrete Americas and its STAR applicator partner, DLS Floors, successfully completed a significant polymer floor installation at a private aircraft hangar in Sugarland, Texas. The hangar, located at Sugarland Regional Airport and owned by local entrepreneur Buddy Fogle, spans almost 15,500 square feet of non-residential construction space, including a 2,300 square feet mezzanine. This facility serves as a home for Fogle's vintage car collection and private planes.
The project involved the application of Flowcrete Americas’ high-traffic polymer flooring system, Flowcoat HTS. This system was specified for installation across the entire hangar at a thickness of 35–40 mils. The client selected a range of custom shades from Fogle’s brand palette to personalize the floor. The installation team from DLS Floors, led by John Guidry, applied Flowcoat HTS to the main floor in Canada gray, complemented by blue walkways and a battleship gray trim.
Flowcoat HTS is a robust flooring system designed for high-traffic environments. It consists of a solvent-free epoxy primer, followed by a pigmented epoxy coating. Once cured, this is sealed with a highly durable, UV-resistant pigmented polyurethane topcoat. This multi-layer system provides a surface highly resistant to abrasion, wear, and chemical exposure, making it well-suited to withstand spills from oil, gas, and aviation fuel, as well as inevitable tire marks, which are common in an aircraft hangar setting.
A notable design element incorporated into the floor installation was the Fogle Aviation logo, positioned prominently at the entrance of the hangar. This detailed logo, measuring 25 feet wide by 7 feet high, was meticulously applied using a custom decal stencil. The DLS Floors team painted within the stencil using Flowseal HTS, the pigmented topcoat component of the standard system, to achieve a precise and visually appealing result.
The decision to use Flowcoat HTS for the hangar floor was based on Fogle’s prior positive experience with the same material. Fogle had previously engaged DLS Floors and Flowcrete Americas for a successful flooring installation at his manufacturing plant in Stafford, Texas, in 2014. That earlier installation demonstrated the material's durability and resilience under heavy traffic and manufacturing operations. Given the stringent requirements for a protective and chemical-resistant floor in an aircraft hangar, Fogle expressed confidence that Flowcoat HTS would be an ideal solution for his new facility.
Protective flooring systems are crucial in aircraft hangars, which are not merely storage spaces but also facilities for essential repair and maintenance of valuable assets. Such systems are necessary to shield the concrete substrate from the corrosive effects of chemical spills, the stresses of heavy loads, and potential impacts. The failure of a floor finish in this environment can compromise on-site safety, disrupt operational capacity, diminish the hangar's value, and lead to costly repairs and maintenance. Therefore, the selection of a high-performance flooring system like Flowcoat HTS is a critical investment for the longevity and functionality of the facility.
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