Smarter Hangars, Safer Assets: NozzleBot™ Brings Precision Suppression to Aviation Fire Safety

Smarter Fire Protection for Aviation Hangars

Autonomous Suppression That Protects While Minimizing Disruption

Protecting aircraft and aerospace assets from fire is a high-stakes challenge. Hangars house valuable, sometimes irreplaceable, equipment, and the complexity of these environments makes mistakes in fire detection and suppression exceptionally costly. Traditional suppression systems such as high-expansion foam and deluge sprinklers mandated by NFPA 409 play vital roles, but they can introduce significant risks, including false activations, operational disruptions, and tragic outcomes.

WatchDog Robotics' NozzleBot™ is an autonomous, precision fire suppression solution engineered to rapidly detect and extinguish fires at their source. By leveraging advanced IR3 flame sensors and thermal video analytics, NozzleBot significantly reduces false alarms, activating quickly and precisely to minimize damage and safeguard personnel and valuable assets.

The Problem with Traditional Foam Systems

NFPA 409 requires high-expansion foam systems for large aircraft hangars to achieve extensive coverage. Although effective at suppressing fires, these systems often activate unnecessarily or accidentally, resulting in severe consequences. Significant damage to sensitive aircraft components and electronics, risk of corrosion, costly cleanup, extended operational downtime, and grounded fleets are common results. Serious life-safety risks, especially suffocation and reduced visibility, compound these issues.

Recent Incidents Demonstrating Risks

Recent events have underscored the risks inherent in foam-based systems. On July 4th, 2025, a foam discharge at a Spirit Airlines hangar led to significant disruptions, grounding aircraft and necessitating costly inspections and maintenance, likely totalling in the millions, although the exact total is to be determined.

Similarly, in 2024, a foam system unintentionally activated at a Mobile, AL Coast Guard hangar, grounding seven aircraft for extensive cleaning and inspections, significantly disrupting the operational capacity of the Coat Guard, a terrifying scenario for those out at sea.

More tragically, two years ago at Wilmington Airport in Ohio, a man lost his life, likely due to suffocation, following an accidental foam discharge. Eight first responders were injured during the incident, with some firefighters needing to be carried out on stretchers after suffering eye injuries from the foam, electrical shocks, and additional physical harm resulting from navigating the foam-filled hangar with severely limited visibility.

Why NozzleBot™ Is the Better Solution

NozzleBot is specifically designed to overcome these traditional system pitfalls. By quickly identifying and precisely suppressing fires at their source, NozzleBot prevents small incidents from escalating into large-scale events that necessitate foam activation. The advanced analytics within NozzleBot virtually eliminate false positives, protecting valuable assets and personnel without incurring the massive disruptions associated with traditional systems. Moreover, NozzleBot is operable with either water or foam, offering flexibility to accommodate specific site requirements and environmental considerations, thus drastically reducing the financial impact compared to traditional foam system discharges.

Using NozzleBot as a Complementary System

In addition to serving as a primary fire suppression system, NozzleBot can effectively operate in parallel with traditional suppression systems. In this complementary role, NozzleBot acts as an advanced first line of defense, rapidly identifying and addressing fires at their earliest stages. By intervening quickly, NozzleBot can prevent the full-scale activation of foam or deluge systems, significantly reducing the likelihood of false alarms and associated damages. This parallel approach enhances overall hangar safety and operational continuity, drastically reducing cleanup expenses, aircraft downtime, and potential injuries or fatalities linked to large-scale foam deployments.

Industry Data and Technical Insights

A comprehensive 2021 University of Maryland study, "Review of Foam Fire Suppression System Discharges in Aircraft Hangars," found that of 174 foam system activations between 2004 and 2019, 137 were accidental, none involving fuel spills. Cleanup costs per incident ranged from $20,000 to $40,000 for just the foam, and average $1,000,000 in total (labor, part cleaning, replacements). That is between $68 and 200 million in aircraft damages and lost business per year according to Aviation Pros and NATA estimates, with a single incident in 2018 costing $25 million (Global Aerospace).

Global Aerospace’s analysis further reinforces that accidental foam activations pose greater risks and costs than actual hangar fires, noting that there is scant evidence supporting the superiority of foam systems over standard sprinklers. These insights underscore that NFPA 409 standards, particularly regarding foam systems, may introduce more economic burdens and hazards than they resolve, particularly in smaller or more modern hangars.

NozzleBot as a Primary Suppression System

In smaller hangars or jurisdictions that embrace innovative fire protection approaches, NozzleBot™ can function effectively as the primary fire suppression system, entirely eliminating the disadvantages of traditional high-expansion foam systems. As a primary suppression method, NozzleBot ensures rapid response times, precisely targeted suppression, and minimal collateral damage.

Key features and benefits include rapid deployment of suppression agents directly at the fire source, dramatically reducing the risk of extensive damage and cleanup costs. Its intelligent detection technology virtually eliminates accidental activations, significantly reducing operational disruptions and downtime. The environmental versatility of NozzleBot, able to use either water or foam, accommodates diverse regulatory and environmental needs. In doing so, NozzleBot not only improves safety outcomes but also offers substantial financial benefits by avoiding the exorbitant installation and maintenance costs associated with traditional foam systems. This solution protects aircraft and personnel while maintaining operational continuity, representing a transformative improvement in fire suppression strategy.

Practical Applications and Case Scenarios

Consider a commercial aviation hangar where a minor electrical event near an aircraft is quickly identified and suppressed by NozzleBot, completely avoiding foam activation and costly aircraft damage. In a private jet maintenance facility, a battery-related fire is extinguished immediately, safeguarding sensitive aircraft systems without the need for extensive foam cleanup. Similarly, in a military UAV hangar, autonomous NozzleBots provide constant surveillance during high-risk refueling operations, significantly reducing potential operational hazards.

Conclusion

Modern fire protection for aviation hangars demands innovative, reliable, and precise solutions. While traditional foam systems fulfill critical safety roles, they also come with substantial risks when activated. WatchDog Robotics' NozzleBot presents a forward-thinking approach, offering smarter, faster, and more targeted suppression capabilities that drastically reduce downtime, damage, and risks to human life, redefining safety standards for aviation hangars. Call us today at 307-231-0416 to learn more and schedule a demonstration.