Case Study: How United Airlines Gave Their Newark Hangar a Brand-New Look with the BlueTex™ Cover System
Case Study: Covering Up Old Airplane Hangar Insulation with BlueTex™
Old insulation has a way of aging a building. Whether it's been torn up over the years, stained, or has just faded into a dingy, uneven mess, worn insulation can make an otherwise solid facility look tired and unprofessional. The good news? You don't have to rip it all out to fix it. With the BlueTex™ cover system, you can install right over your existing insulation and create a fresh interior vapor barrier that's bright, clean, and built to impress. Below is a great example of that approach on a big scale.
Background
Many facilities are looking for a way to conceal outdated insulation that has become damaged, discolored, or worn over time—leaving the space looking unattractive and unprofessional. This customer, United Airlines, needed to refresh the interior of a massive 60,000 square-foot airplane hangar at their Newark, New Jersey location. The existing insulation was old and worn, and they were working against a tight timeline: the hangar would only be empty for a limited window, and the install had to be done before it was back in use.
Project Details
Type of Structure: 60,000 Sq Ft Airplane Hangar and Filming Studio
Install Date: July/August 2026
Location: Newark, New Jersey
Goal: Cover old insulation without removing it, to create a fresh, clean interior surface — on a tight timeline
Product Used: 2mm BlueTex™ Pro 50" Wide
Install Details
Because United Airlines needed to make the most of a short window when the hangar would be empty, speed was everything. We worked closely with their team to get them samples, create a custom quote for their facility, and help get their order placed and shipped out quickly so they could get to work right away and meet their deadline.
Since they were covering over the old insulation rather than removing it, the prep work was minimal. The crew went right over the existing insulation with the BlueTex™ cover system, creating a brand-new interior vapor barrier across the walls without the time and mess of a full tear-out.
Finish
The BlueTex™ was installed creating a fresh interior vapor barrier with a clean, bright, professional appearance across the entire hangar. This space is used for filming so the improvements made a big impact. This Cover System method is great for large spaces like this—where the building needs to look presentable for crews, staff, and operations—and it gets the job done fast.
Results
By covering the old insulation instead of removing it, United Airlines transformed the look of their 60,000 square-foot hangar within their tight timeline and had the space ready to go when they needed it. The result is a bright, clean, professional interior that looks brand new. The hangar hosted United Airlines employees, executives, and media (including the company's CEO, Scott Kirby) for an unveiling ceremony showcasing their brand-new aircraft.
That's a dramatic difference — the before/after that the BlueTex™ cover system delivers is unlike no other insulation out there.
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Interested in improving the look of your building's old insulation? If you have a project like this and are wanting to know how BlueTex™ can help, contact us for more info or fill out the form on the bottom of this page to get a quote fast.