Walk This Way: 10 Airplane Flooring Facts

Before they purchase new flooring, airlines have to figure out what to do with the old material. Mohawk Group, flooring specialists that work in a multiple of industries, estimates 6 billion lb. of carpet waste goes into landfills each year. The company created a program, ReCover, that arranges for containers and shipping to reclamation centers for a fee.

The most common material for carpet is wool, but there are blends and new materials that offer unique proprieties. Mohawk Group features flooring made out of Skylon, a woven nylon carpet hybrid. Floorings and upholstery need to meet specific FAA requirements regarding flammability, smoke and toxicity. Deaths occur from a crash not just because of impact, but also because of the smoke or toxins released when materials burn. Airbus and Boeing have additional standards for fire and flammability testing flooring manufacturers should meet.

SkyPaxxx Interior Repairs exclusively distributes Sky-Tiles, manufactured by Interface, a 100% recyclable carpet option that offers installation without removing seats, selective replacement and drop-in retrofits. To start the process, SkyPaxxx asks for a customer's current carpet layout and a sample, which is used to create a "Sky-Tiles" map. A first run of the carpet can take six to eight weeks, but if the customer chooses something in stock, the material can be sent in two weeks.

This carpet is being fitted on an Air Nostrum ATR 42. Typically, airlines or MROs install carpets themselves. For specific products, training or crews can be provided by the manufacturer or distributor. Installation time depends on the aircraft size and if it is a complete installation or section replacement.

This project for new carpet was completed on an Omni Air Boeing 767. SkyPaxxx once completed a project for a Boeing 737-700 in four man-hours, but Rick Lockhart, president of SkyPaxx, says a Boeing 737-800 takes, in general, around eight man-hours for a carpet installation. 

Lockhart also says, "Most airlines historically replace the carpet every six to 12 months, and the rest of the set every C check. Being able to keep carpet installed in the aisle for 18 months and the rest of the aircraft two C check cycles represents huge savings in manpower, aircraft downtime, raw material purchasing, cutting and serging costs, and administrative expenses." Carpet or flooring comes with cleaning and replacement recommendations from the manufacturer. Using the wrong cleaning solution can warp and shrink the carpet.

During certain checks, sometimes only a portion of the carpet needs to be replaced. For example, the carpet between the lighted safety walkway can be changed independently of the rest of the carpet. Pictured here is STG Aerospace saf-Tglo, a photolumniscent walkway that doesn't require batteries or traditional lights. Saf-Tglo is installed by cutting the material to length, then applying using the same double-sided tape used in carpets. The photolumniscent technology comes in up to 300 different colors, and can also be custom created to match an aircraft's branded interior pattern.

In July, Orbis, the non-profit organization that fights blindness, installed STG Aerospace saf-Tglo in its Flying Eye Hospital. The MD-10-30CF houses a fully accredited ophthalmic teaching hospital that trains and treats patients internationally.

An airline operator may want to replace electrical systems that light the flooring with photoluminscent options to reduce maintenance and avoid complications. If an aircraft's exit signs and walkways are not lit properly, the flight can be grounded until the issue is resolved.

STG Aerospace also provides supplemental type certificates for FAA- and European Aviation Safety Agency-approved aircraft types. Once installed, the cabin lights need to be set to bright to perform a system charge daily. This charge time can change, depending on the aircraft type.