Don’t Put Your Business Aircraft at Risk: Paint Pros Share Best Practices

Business aviation managers and maintenance technicians know that the value of an effective aircraft paint job goes well beyond appearance alone. Not only does paint protect against damage from moisture, dirt and harmful pollutants, but chipped, cracked or improperly maintained paint can ultimately threaten the aircraft’s structural integrity and impact safety.

With so much at stake, business aircraft paint professionals shared their top do’s and don’ts, as well as important guidance on choosing the best shop for your operation.

“High-quality aircraft paint is vital,” said Vice President of Dean Baldwin Painting Rick Smith. “It serves as a protective barrier between the aircraft’s aluminum or composite fuselage and harsh environmental elements. This protection includes corrosion resistance and UV shielding, which is especially important for newer composite aircraft.”

“A well-executed aircraft paint job ensures that the exterior surface of the aircraft has been stripped and visually inspected for corrosion and defects,” said Sales Manager Adam Bruce at NBAA member Duncan Aviation.

Proper maintenance always starts with prep work, and skipping essential steps can spell trouble down the line. After preparation, technicians apply protective materials including primer, filler, sealant – and then the paint. “This process properly protects aircraft skin and seams from moisture and other environmental factors like salt, dust, pollution and sun,” said Bruce.

Aerospace-grade paint allows for expansion and contraction of the aircraft. Application is also a key factor. Misapplied paint can drastically affect expansion and contraction tolerances, as well as alter the performance of the paint. In some cases, incorrectly applied paint fails immediately. When that happens, there will be peeling or even areas where the paint comes off in large “sheets,” Bruce said. In other cases, paint may crack, pop or show other defects that point to inconsistent application or failure.

Paint Maintenance Do’s and Don’ts

Painting should occur “roughly every seven years, with 10 years being the longest aircraft should remain unpainted,” said Bruce. Waiting longer could cause harm and impede aircraft functionality. “Failure to strip and repaint aircraft in that timeframe means potential hidden corrosion is undiscovered and can drastically worsen, requiring more invasive and costly repairs.” Paint wears better and longer in concert with a hangar and a set cleaning schedule.

“Some of the newer base coat and clear coat systems claim durability of up to 10 years,” Bruce said, but actual paint longevity depends on the quality of the application and how the aircraft is operated and maintained. Follow the manufacturer’s recommended guidelines.

“Most operators build the cost of aircraft paint polish into their operating budget,” said CEO Stephen Hooks, of RealClean Metro Atlanta, an NBAA member.

“Ideally, flight departments should polish their airplanes at least once per annum.” Contaminants damage the surface and increase drag. “The consequence of neglecting the aircraft paint could bring huge financial ramifications later,” Hook said. “This translates to a polish cost quote that is 10% of a completely new paint job.”

“Depending on the environment, wet wash once a week at a minimum,” said Paint and Interior Sales Manager Adam Doyle at NBAA member Elliott Aviation.

“Do a general walkaround daily, looking for bubbles under the paint, which could be corrosion or sheen differences.”

Key Questions in Choosing a Paint Facility

Repainting an aircraft is a major maintenance event. Choosing the proper facility is essential and requires research, thought and consideration. Experts shared these important things to ask about:

• Is the facility an FAA-approved repair station?
• Does it have strong customer references?
• Does its staff have extensive experience?
• How many paint events does the facility complete per year?
• What materials does the shop use, and what does it recommend?
• Does the shop offer a warranty for its work? If so, what is the length of coverage?

“Effective environmental controls are crucial, including proper air filtration, ventilation, humidity control and temperature regulation to accommodate year-round climate variations,” Smith said. Additionally, the facility should be well-versed in all available pre-coating systems and use only OEM-approved primers and topcoats.

How to Minimize Aircraft Painting Downtime

To minimize total downtime, it’s also a good idea to make sure your chosen facility has the proper tools that will enable it to coordinate your aircraft’s paint job with other in-house clients.

At least 30-60 days ahead of the job, it helps to be intentional about selecting the paint scheme and application for the aircraft. Alert the paint shop of any possible concerns related to corrosion or exterior defects. This can help the paint technicians better align their resources to meet the scheduled completion date.

Finally, at input, request that a paint shop representative and designer perform a walk around the aircraft – with you or your representative – explaining how various areas of the aircraft will be addressed during the paint process. This avoids questions and assumptions that sometimes creep in later in the process, and that may create delays in delivery.