Key Takeaways
- There is no single repaint interval. FAA corrosion guidance leaves inspection frequency to the operator and the manufacturer’s programme and sets no repaint date.
- Published rules of thumb are vendor guidance. Sherwin-Williams cites about ten years for a typical general aviation aircraft, and AkzoNobel says aircraft tend to go into maintenance every six or seven years, often repainted with coating life left.
- Condition should trigger refinishing: cracking, fading, erosion, blisters, flakes, chips, lumps and any corrosion near fasteners or edges.
- For a fleet, record coating condition at every hangar visit, then decide between touch-up, panel work and a full strip.
The usual question is how many years should pass between repaints. The honest answer is that the number comes from the aircraft’s condition, not the calendar. This guide covers what published sources say, which signs should trigger work and how to build a schedule across several tail numbers.
What Do Published Repaint Intervals Say?
Very little that works as a rule. The figures that exist come from vendors and describe different kinds of aircraft:
| Source | What it says | Caveat |
|---|---|---|
| AkzoNobel Aerospace Coatings, April 2023 | Aircraft tend to be taken out of service for maintenance every six or seven years, without knowing for certain that a repaint is needed. “Planes are often repainted while the coating still has life left in it.” | Sells a coating-monitoring service. |
| Sherwin-Williams Aerospace, aircraft painting FAQ | A typical general aviation aircraft is repainted about once every ten years, and the right frequency depends on hours flown, storage, care and conditions. | Sells coatings; undated FAQ about general aviation, not an airline fleet. |
| FAA AC 43-4B, September 2018 | Corrosion inspection frequency is the operator’s responsibility, set by the AC, the manufacturer’s recommendations or the operator’s own programme. It gives no repaint interval. | Guidance; a published manufacturer programme takes precedence. |
Treat any calendar figure as a planning starting point, not a limit.
Which Signs Tell You Refinishing Is Due?
Sherwin-Williams lists cracking, fading, erosion and visible corrosion, and says corrosion around rivets or leading edges needs an expert’s review. The FAA adds why waiting is risky: paint can mask early corrosion, so surfaces should be inspected often for blisters, flakes, chips and lumps (AC 43-4B, paragraph 2.3.2).
Filiform corrosion deserves attention. AC 43-4B describes worm-like traces beneath a paint film that start at breaks in the coating and can lead to intergranular corrosion around fasteners and seams if left untreated.
Our working rule, which is ours and not a standard: isolated chips or a blister along one fastener line point to panel-level rectification, while cracking across several areas, filiform traces or corrosion found in more than one zone point to a full strip.
What Makes Paint Wear Faster?
Sherwin-Williams points to hours flown, hangar storage, washing, flying conditions, saline takeoffs and landings, and UV exposure.
AC 43-4B backs this up. Salt air, heavy pollution and over-water operations call for a more stringent corrosion programme (paragraph 1.8.1), and high temperatures speed corrosion by raising reaction rates (paragraph 2.4.3). Filiform corrosion occurs when relative humidity is between 78 and 90 percent and the surface is slightly acidic, and storing aircraft below 70 percent relative humidity helps prevent it.
For a fleet in a hot, humid region, read those passages as a reason to inspect more often. We found no published figure that puts a number of years on UAE conditions, so we don’t offer one. Covered storage also helps, as our guide to hangar versus outdoor parking explains.
Should You Strip, Overcoat or Touch Up?
AC 43-4B recognises touch-up and overcoating, and requires aged paint to be scuff-sanded so new paint adheres. For a full repaint, Sherwin-Williams recommends stripping all existing paint and having a trained professional confirm the airframe is sound before pretreating, priming and applying the topcoat.
Extra coats can upset control surface balance. FAA AC 43.13-1B (paragraph 4-36b) tells mechanics not to add coats beyond what the manufacturer originally applied to balanced control surfaces. Repeated overcoating adds coats, so a full strip is the cleaner reset.
Our aircraft refinishing and painting service covers a full exterior strip, corrosion control, surface preparation, livery application and targeted touch-up, with the scope agreed before work begins. When stripping reveals corrosion, we document it, discuss it with you and agree the rectification scope before proceeding.
How Do You Build a Fleet Refinishing Schedule?
- Inspect and record on a fixed cadence. AkzoNobel’s fleet service logs dry film thickness, colour variation, gloss and general appearance. Record the same four items for each tail, with photographs.
- Review at maintenance and storage events. Set a review window per tail instead of a fixed repaint date. Our site can run refinishing alongside storage or base maintenance without the aircraft leaving.
- Choose the scope at each review: touch-up, panel-level or full strip.
- Plan the downtime. Sherwin-Williams puts shop time for a standard smaller aircraft at 10 to 15 days, and Duncan Aviation quotes 22 calendar days standard downtime for a complete strip and repaint. Corrosion found at strip extends both. At Dolphin Air, duration depends on airframe size, coating condition, livery complexity and corrosion found, and we confirm it once scope is agreed.
What Should You Ask Any Aircraft Painter?
- Which coating system will be used, and does it fit the manufacturer’s instructions?
- How is control surface balance handled after painting?
- How are corrosion findings treated? Expect them to be documented and agreed with you first.
- What does the warranty cover, in years and hours?
- Can storage or maintenance run at the same site? Our site handles business jets, turboprops and narrow-body commercial aircraft, and specifics vary by airframe and current facility activity.
Frequently Asked Questions
How often should an aircraft be repainted?
It depends on condition, use and storage, not a fixed number. Sherwin-Williams cites about ten years for typical general aviation aircraft, and AkzoNobel notes aircraft tend to be taken out of service for maintenance every six or seven years and are often repainted with coating life remaining. Inspect, record and decide on the evidence.
What are the signs an aircraft needs refinishing?
Cracking, fading, erosion, blisters, flakes, chips, lumps and visible corrosion, particularly around rivets, fasteners, seams and leading edges.
Can you paint over old paint?
Touch-up and overcoating are recognised if the aged surface is scuff-sanded first. For a full repaint, the paint maker recommends stripping, and the FAA cautions against extra coats on balanced control surfaces.
How long does repainting an aircraft take?
Published shop figures include 10 to 15 days for a standard smaller aircraft and 22 calendar days for a complete strip and repaint at one business aviation shop. Corrosion, size and livery complexity all change it, so ask for a duration based on your scope.
Scope Your Refinishing Schedule
Send us the aircraft type, coating condition and target dates, and our operations team will confirm scope and a realistic duration.
