Asphalt repair and resurfacing for a private aircraft hangar in Englewood, Colorado
At Centennial Airport in Englewood, Colorado, an aging asphalt hangar floor needed a practical repair strategy that could restore service without the disruption and cost of full-depth replacement. The project covered approximately 1,200 square feet and included a trench repair at the hangar entrance, followed by a 1/2-inch resurfacing application across the existing asphalt substrate. The surface was decades old, had been painted previously, and presented prep challenges due to petroleum-rich asphalt, a porous and uneven profile, and Colorado’s dry, high-altitude conditions.
The Problem
The existing asphalt surface inside the private plane hangar had reached the point where appearance, serviceability, and long-term reliability were all concerns. Full-depth replacement would have meant significantly higher cost, more disruption, and a longer shutdown window. Instead, the contractor needed a repair and resurfacing approach that could address localized deterioration at the entrance trench while also renewing the larger traffic surface with a clean, uniform finish.
Surface preparation was one of the biggest technical hurdles. Traditional mechanical prep methods were not ideal for this substrate. Grinding was reported to gum up quickly because of petroleum content in the asphalt, while shotblasting risked damaging the softer surface. The crew removed what they could with hand grinders, then pressure washed to complete prep. The existing surface was porous and uneven enough that bond wasn’t a concern.
Environmental conditions also increased the degree of difficulty. Placement took place from late March 2025 to early April 2025 in very dry weather, with temperatures around 45-50 degrees Fahrenheit and a strong breeze. On a fast-setting repair, those conditions can accelerate moisture loss and reduce finishing time, making material control and finishing technique critical to the outcome.
The Solution
To restore the hangar floor efficiently, the crew used Rapid Set Asphalt Repair Mix for the cut-out trench repair at the entrance and Rapid Set Asphalt Resurfacer for the 1/2-inch resurfacing application across the hangar floor. Asphalt Repair Mix is a cement-based, flexible, fast-setting pothole fill and repair material designed for full-depth repairs up to 24 inches, with little to no subsidence, strong bond to existing asphalt, washout resistance, and greater durability than conventional asphalt. Asphalt Resurfacer is a fast-setting, cementitious asphalt repair and resurfacing material with approximately 20 minutes of working time, drive-on strength in about 2 hours, superior adhesion to asphalt, and the ability to be extended with coarse aggregate for thicker applications.
That product combination matched the project requirements well. The trench at the entrance called for a material capable of handling deeper localized repair without settling, while the broader hangar floor needed a resurfacing system that could create a renewed wearing surface over existing asphalt without forcing a full tear-out. The cement-based nature of both products also supported a more stable, durable repair strategy than a conventional asphalt patch for this type of restoration work.
The installation team used a controlled placement process tailored to the jobsite environment. They mixed with a rigid drill mixer in a Hippo bucket, used three-bag mixes, and dosed each bag with one packet of Set Control to extend working time. They also used midpoint water quantities between the published high and low tolerances, a practical move for balancing flow and finishability in dry field conditions. To offset rapid surface drying and reduce the risk of flashing, the crew pre-misted the substrate before placement.
Finishing methods were equally important to the success of the job. The resurfacer was placed with a gauge rake, then finished with a nap roller. According to the project notes, the product’s polymer-rich, sticky consistency made the nap roller the better choice for producing a more uniform texture and appearance. The contractor specifically reported that the nap roller was essential to achieving a finish that still looked like asphalt while cleaning up the surface after gauge raking.
The Result
The result was a renewed airport hangar surface that delivered both functional repair and visual improvement without the cost of full replacement. The resurfaced floor achieved a uniform asphalt-like aesthetic with no pinholes. The finished project made an immediate positive impression that resulted in other owners stopping by to ask about resurfacing their own hangars.
From a contractor standpoint, the project shows many practical takeaways. First, cement-based asphalt repair materials offer a strong alternative when owners want to extend pavement life and avoid major reconstruction. Asphalt Repair Mix resists cracking, stays intact in service, prevents washout, and offers higher durability than conventional asphalt, while Asphalt Resurfacer combines fast return-to-service characteristics with strong adhesion and resurfacing versatility. Those attributes are especially relevant for airports, hangars, industrial yards, and other facilities where shutdown time matters, and full replacement is hard to justify.
Second, the project reinforces the importance of adapting installation methods to the substrate and environment. On older asphalt in a high-altitude, low-humidity climate, pre-misting, frequent tool cleaning, gauge-rake placement, and the use of a nap roller were not minor decisions. They were process choices that helped the crew maintain workability, improve finish quality, and avoid defects during placement. The contractor also noted that Set Control was frequently necessary in that environment, even at relatively cool temperatures, which is useful field insight for crews working in similar conditions.
Most importantly, the owner avoided a much more expensive full-depth replacement. The asphalt resurfacing approach saved many thousands of dollars while still producing a durable, visually improved surface. Contractors can make targeted repair where needed, resurfacing where it makes sense, turnaround projects faster, and achieve an outcome that builds owner confidence.
Takeaways
For contractors evaluating repair options on aged asphalt substrates, the Centennial Airport project highlights a repeatable approach.
