Taxiways, Aprons & Runways: A Buyer’s Guide to FAA compliant Airport Stencils

Airport stencils that meet FAA standards start with the right plan

If you manage airfield markings, you know accuracy is not optional. The right airport stencils help you deliver crisp, repeatable markings across taxiways, aprons, and runways while keeping your project aligned with FAA guidance. This buyer’s guide explains how to choose FAA compliant airport stencils, what materials and sizes to consider, and how to plan a smooth installation that stands up to aircraft traffic and weather. Whether you need surface painted hold signs, runway numbers, or apron safety zones, the details below will help you specify with confidence.

Why FAA compliant airport stencils matter

Airport markings are a language. Pilots, vehicle operators, and ground crews rely on consistent symbols, colors, and dimensions to move safely and efficiently. FAA guidance standardizes that language so every hold line, number, and directional arrow looks and reads the same way from airport to airport. Using airport stencils designed around those standards helps you:

• Save time during layout with repeatable, scalable patterns

• Achieve consistent letter, numeral, and bar widths across large areas

• Reduce rework and change orders thanks to compliant sizing

• Produce sharp edges that improve legibility and retroreflectivity

• Extend service life by keeping paint within the intended footprint

When you combine quality airport stencils with the right paint system and beads, your markings last longer and meet the visual performance targets your airport needs day and night.

Know your pavement zones: taxiways, aprons, and runways

Each part of the airfield has a distinct set of markings and, in turn, airport stencils suited for that task. Understanding the zone helps you choose the correct stencil kits and sizes.

Taxiways

Taxiways guide aircraft between runways, aprons, and hangars. The markings focus on guidance and control. Common taxiway stencil needs include surface painted holding position signs at runway entries, taxiway direction and location identifiers, ILS or POFZ hold markings where applicable, and surface arrows for complex intersections. Characters are large and legible at speed, and colors follow FAA guidance such as yellow for taxiway guidance and red or black backgrounds for signs painted on the surface.

Aprons

Apron areas are about parking, servicing, and safety. Airport stencils here support gate lead-ins, stand identification, fuel and equipment zones, no entry blocks, and safety buffers around jet blast and equipment paths. Because aprons are busy with ground vehicles and personnel, markings benefit from durable materials and clear wording stencils for operational messaging.

Runways

Runways require the strictest conformity. Airport stencils are used for runway designator numbers and letters, aiming points, threshold markings, touchdown zone bars, chevrons, and arrows for displaced thresholds or blast pads. Runway numbers can be very large, and the thickness and spacing of bars are defined by tables in FAA guidance. Good stenciling minimizes overspray and keeps sharp edges that support retroreflective bead retention.

Standards and sizing best practices for airport stencils

The FAA Advisory Circular that governs airport markings outlines colors, shapes, placement, and size. Your stencil set should align directly with those specifications. While the exact values vary by runway width, approach category, and airport type, here are practical best practices that keep projects compliant and efficient:

• Scale to pavement width and aircraft size. Runway numerals and bars for a 150 foot runway can be much larger than on a smaller general aviation strip.

• Follow the letter and numeral style shown in FAA figures. The character shapes are not typical roadway fonts.

• Use surface painted sign stencils with built in borders when the spec calls for black or red backgrounds with contrasting characters.

• Verify hold short, ILS critical area, and POFZ symbols with current drawings before ordering. Small geometry differences matter.

• Keep a record of stencil sizes used at each location. Consistency simplifies future maintenance and repainting.

If you are unsure which size set to select, a stencil supplier that understands airport markings can review your runway and taxiway widths and recommend the correct scale. 1-800-Stencil consults on sizing so you can order once and install with confidence.

What to look for when buying airport stencils

Airport projects demand durable materials, precision cuts, and smart features that speed up layout. Use these criteria to compare options.

Material and thickness

Most professional airport stencils are cut from engineered plastics that resist solvents and repeated cleanings. 1-800-Stencil manufactures in LDPE and UHMW to match your durability needs:

• LDPE provides a flexible, cost effective option that lays flat and cleans easily. It is popular for larger surface painted sign panels and general lettering.

• UHMW is tougher, with high abrasion resistance for long term reuse on high volume projects. It stands up well to repeated placements, aggressive cleaning, and heavy crews.

Common thicknesses are chosen to balance weight, flexibility, and life. Thicker sheets resist wind lift and reduce under spray while thinner sheets are easier to handle in tight spaces. Ask for recommendations based on the markings you plan to apply.

Cut quality and edge fidelity

Clean, burr free cuts produce crisp lines and reduce paint creep. Precise kerf control matters on numerals, complex arrows, and multi panel signs. Look for CNC cut stencils with smooth edges and consistent geometry.

Panelization and registration

Large airport stencils often ship in panels. Good systems include alignment marks and registration features so crews can position panels quickly and repeat patterns accurately. This is especially helpful for long hold bars, runway numbers, and multi color surface painted signs.

Reusability and cleanability

Quality airport stencils allow you to scrape or flex dried paint off without cracking. They should tolerate typical pavement marking solvents without distortion. UHMW in particular is known for long reusability cycles.

Runway, taxiway, and apron stencils you will likely need

Every airport is unique, yet most projects share a core set of airport stencils. Use this checklist as a starting point and adjust based on current plans and FAA guidance.

1. Runway numerals and letters sized to your runway width

2. Threshold bars, aiming points, touchdown zone bars, chevrons, and arrows as applicable

3. Taxiway centerline arrows for complex turns and fillets

4. Surface painted holding position signs at runway entries

5. Direction and location surface painted signs on taxiways

6. ILS or POFZ hold markings where required

7. Apron stand identifiers and gate lead-in alignment aids

8. Safety buffers, no entry areas, and equipment or fuel zone wording

9. Distance remaining markers if required on runway shoulders

1-800-Stencil offers standard airport stencils for many of these applications and can build custom sizes to match specific drawings if your project requires them.

LDPE vs UHMW: choosing the right stencil material

Both LDPE and UHMW are proven for airport stencils. Your decision depends on project scale, crew preference, and lifecycle goals.

• Choose LDPE when you want flexible, easy handling panels that lie flat fast and store compactly. This is a great everyday choice for surface painted signs and wording.

• Choose UHMW when you need heavy duty durability for large airports, repeated mobilizations, and intense cleaning cycles. The material resists abrasion and warping over many uses.

Either option from 1-800-Stencil is reusable, solvent resistant, and cut to precise dimensions for sharp results.

Application tips for crisp, durable airport markings

Even the best airport stencils need a solid process on site. These tips help you get professional results that last.

• Confirm substrate readiness. Clean the surface, remove chalking and loose paint, and ensure pavement is dry and within temperature range for your coating.

• Snap centerlines and reference points. Use layout strings, chalk, or temporary tape to speed placement and alignment.

• Secure the stencil. Weigh down edges or use approved low tack tape to prevent lift when spraying.

• Spray in light passes. Multiple light coats reduce under spray and improve edge sharpness.

• Bead while wet if required. Apply glass beads uniformly to meet retroreflectivity targets.

• Lift carefully. Remove the stencil steadily to avoid smearing. Place it onto a clean tarp for transport.

• Clean promptly. Flex stencils to flake dried paint or wipe with compatible solvent following safety data guidelines.

Follow all airport safety procedures, including NOTAMs, escorts, and marking closures, and verify final placements against approved drawings before opening to traffic.

When to order custom airport stencils

Pre made airport stencils cover many standard needs. Custom stencils are a smart choice when you have unique geometry, special stand IDs, branding on aprons, or nonstandard sizes on legacy pavements. 1-800-Stencil can convert your CAD or PDF into cut ready files and provide proofs for approval. Custom solutions help you maintain consistency across terminals, carriers, and maintenance cycles.

About 1-800-Stencil

1-800-Stencil is a leading supplier of high quality pavement marking stencils based in Alsip, Illinois. The company builds pre made and custom stencils for parking lots, roads, highways, bike lanes, crosswalks, airport runways, and industrial safety markings. Stencils are crafted from durable LDPE and UHMW for longevity and repeat reuse. Known for quality, innovation, and service, 1-800-Stencil supports contractors, airports, municipalities, and facility teams nationwide.

Products and services include alphabet and number kits, arrow stencils, handicap symbols that support ADA compliance, retail stencils for chain standards, DOT stencils matched to state and city specs, wording stencils like NO PARKING or NO ENTRY, and fully custom stencils for unique needs. The airport stencils range covers runway numerals, hold bars, surface painted signs, and apron identifiers, all designed to help you install markings that match FAA guidance.

1-800-Stencil was acquired by RAE Products & Chemicals Corporation, bringing together stencil expertise with RAE’s pavement marking paints, beads, and coatings. This combination lets you source both your airport stencils and your materials from one trusted partner. To discuss a project, call 1-800-STENCIL or email info@1800stencil.com.

How to spec airport stencils for your next project

Use this quick process to build a complete, compliant stencil list before you order.

1. Gather drawings and references. Pull the current airport marking plans, details, and applicable FAA guidance for your project type.

2. Identify each pavement zone. Separate runway, taxiway, and apron needs so you can scale items correctly.

3. List each marking. Note every symbol, number, letter, arrow, and sign to be surface painted.

4. Confirm sizes and fonts. Check the specified character height, stroke width, and border widths where applicable.

5. Select materials. Choose LDPE or UHMW and a thickness based on project duration and reuse goals.

6. Add extras. Include alignment guides, spacers, interlocking sections, and transport sleeves to protect your investment.

7. Review with the supplier. Share plans with 1-800-Stencil to verify selections and streamline production.

Why choose 1-800-Stencil for airport stencils

Airport work is high stakes and schedule sensitive. 1-800-Stencil helps you hit both the spec and the schedule with:

• Precision cut stencils for FAA compliant markings across runways, taxiways, and aprons

• Material options in LDPE and UHMW that balance handling and durability

• Custom fabrication with fast proofs and reliable lead times

• A full catalog that extends beyond airport stencils to roadways, lots, and facilities for one stop ordering

• Backed by RAE Products & Chemicals for a complete solution that includes paint and beads

• Responsive support from estimating through delivery and aftercare

From a single runway renumbering to a full field remark, 1-800-Stencil brings the experience and capacity to keep your team moving.

Care, storage, and long term value

Protecting your airport stencils extends their life and reduces total project cost. After each use, remove residual paint by flexing or scraping with a plastic tool to avoid edge damage. If needed, wipe with approved solvent and allow to dry fully. Store flat, or hang larger panels to prevent warping. Keep panels grouped and labeled by location to speed future mobilizations. With proper care, LDPE and UHMW airport stencils deliver many repeat uses with consistent performance.

Frequently asked questions about airport stencils

Do I need custom stencils for every airport project?

No. Many markings are standard. Custom airport stencils are most useful for nonstandard sizes, special apron identifiers, or branding. 1-800-Stencil can help you decide when custom adds value.

Which material should I choose: LDPE or UHMW?

LDPE is flexible and budget friendly, ideal for most taxiway signs and wording. UHMW offers maximum durability and reusability for high volume or long term projects. Both deliver clean, sharp results.

How do I pick the correct size for runway numbers and bars?

Size is tied to runway width and other factors in FAA guidance. Share your runway data with 1-800-Stencil and they will recommend the correct size set. Many large runways use very large numerals, while smaller facilities use scaled versions.

Can airport stencils be reused across multiple projects?

Yes. With proper cleaning and storage, quality LDPE and UHMW stencils can be reused many times. UHMW offers the longest service life if you plan frequent mobilizations.

What paints work best with airport stencils?

Work with coatings approved for airfield use, including waterborne or solvent systems that accept glass beads. RAE Products can help you select a system that meets performance and environmental needs for your climate and traffic level.

Get started with 1-800-Stencil

When the job calls for accurate, repeatable, and FAA compliant airport stencils, partner with 1-800-Stencil. You will get guidance on sizing, material selection, and panelization along with quick turnaround on both standard and custom items. Backed by RAE Products & Chemicals, 1-800-Stencil can also supply the paints and beads you need for a single source solution. Call 1-800-STENCIL or email info@1800stencil.com to request a quote or submit your drawings. Your airfield markings will look sharp, read right, and stand the test of time.