Hangar Rash: When a Small Slip Costs a Big Sum

In the aviation world, few things appear more routine than moving aircraft around a hangar or on a ramp. But behind these familiar maneuvers lies a surprising truth: they are among the most high-risk operations on the ground—and the cost of error is staggering.

The True Cost of Hangar Rash

“Hangar rash” is the industry term for accidental aircraft damage that occurs during ground handling—often during parking, towing, or repositioning near hangars and ramps. While the term might sound minor, the financial consequences are anything but. According to industry data:

• 83% of ground incidents happen during aircraft movement near hangars or ramps.

• In the United States alone, direct aircraft damage costs exceed $1.2 billion annually.

• When you factor in indirect costs—downtime, labor disruption, insurance hikes, and reputational damage—the total reaches nearly $5 billion.

  

  
  

From cracked fuselages and dented wings to damaged avionics and support equipment, hangar rash isn’t just a logistical setback—it’s a multi-billion dollar problem impacting FBOs (Fixed-Base Operators), MROs (Maintenance, Repair & Overhaul providers), and flight departments across the country.

Why It Happens—Even to the Best Crews

Unlike airborne operations, ground movements often rely more on human judgment than advanced avionics. Crews work in dynamic, congested environments with limited visibility, tight clearances, and pressure to maintain turnaround times. Even the most experienced teams can fall prey to human error—one missed hand signal, misjudged distance, or unaccounted-for obstacle can result in extensive damage.

And with increasingly complex aircraft designs and rising maintenance costs, even minor incidents can quickly escalate into six- or seven-figure repair bills—not to mention potential flight cancellations, insurance claims, and regulatory reviews.

The Hidden Business Risk

Hangar rash isn’t just an operational issue—it’s a business risk. For every accident, there’s not only physical damage but also:

• Revenue loss from grounded aircraft

• Customer dissatisfaction and contract disputes

• Operational downtime that affects scheduling and resource allocation

• Liability exposure that may increase insurance premiums or trigger audits

  
  

These ripple effects can impact profitability, brand reputation, and safety scores—particularly for high-traffic FBOs and precision-driven MROs.

So Why Are We Still Playing a Billion-Dollar Game of Chance?

The reality is that many ground movement processes remain largely manual—dependent on visual cues, radio calls, and legacy procedures. In an era of automation, predictive analytics, and AI-powered safety systems, this gap in ground operations is both glaring and solvable.

At Airtrek Robotics, we believe it’s time for a smarter, safer, and more accountable approach. That’s why we’re building next-generation solutions that bring precision, intelligence, and automation to ground movements. With systems designed to augment human performance and reduce costly errors, we’re making sure every maneuver counts.

What’s Next?

Billions of dollars in preventable damage shouldn't be the norm. Stay tuned as Airtrek rolls out a transformative solution designed to protect aircraft, empower crews, and safeguard your bottom line.

Because in aviation, routine should never mean risky.