FAA Announces Plan to Retire Windows 95 and Floppy Disks from Air Traffic Control

Figure 1: Visual representation of the BeyondTrust vulnerability chain

The Federal Aviation Administration announced on June 26, 2025, a detailed timeline for retiring legacy computing systems from its air traffic control infrastructure. The modernization effort targets Windows 95 workstations and floppy disk-based data transfer mechanisms that continue to operate at multiple FAA facilities, some of which have been in service for nearly three decades.

The announcement follows years of Government Accountability Office reports highlighting the risks posed by aging technology in critical aviation infrastructure. According to FAA documentation, certain air traffic control facilities still rely on 3.5-inch floppy disks to transfer flight plan data between systems that lack network connectivity. Windows 95 workstations remain in use at several Terminal Radar Approach Control (TRACON) facilities for specific display and monitoring functions.

The FAA's plan calls for phased replacement beginning in fiscal year 2026, with full retirement of legacy systems targeted for completion by 2030. The agency estimates the modernization effort will cost approximately $1.2 billion, funded through existing NextGen program allocations and supplemental appropriations.

Air traffic controllers, airlines, and aviation safety advocates have expressed mixed reactions. While the modernization is broadly welcomed, some controllers have raised concerns about transition risks and the reliability of replacement systems. The FAA stated that parallel operations will continue during the transition period to ensure no disruption to air traffic services.

On June 26, 2025, the FAA released a detailed modernization roadmap addressing legacy technology in its air traffic control infrastructure. The document, published through the NextGen program office, acknowledges that certain critical systems continue to operate on technology platforms dating to the mid-1990s.

The FAA confirmed that Windows 95 workstations remain operational at 17 TRACON facilities, primarily for radar display functions and flight data processing. These systems were installed between 1996 and 1999 as part of earlier modernization efforts and have remained in service due to the complexity and cost of replacement.

Floppy disk usage persists at facilities where legacy systems lack network interfaces. Controllers at these locations transfer flight plan amendments and weather data using physical media, a process that the FAA characterized as "operationally adequate but technologically obsolete."

The modernization timeline specifies:

• Fiscal Year 2026: Begin procurement of replacement workstations and networking equipment
• Fiscal Year 2027: Deploy replacement systems at five pilot facilities
• Fiscal Year 2028-2029: Nationwide rollout to remaining facilities
• Fiscal Year 2030: Complete retirement of all Windows 95 systems and floppy disk processes

Figure 2: How the authentication bypass vulnerability works

Operational Continuity: The FAA emphasized that legacy systems, while outdated, have maintained reliable operation. According to agency statistics, Windows 95 workstations at TRACON facilities have achieved 99.7% uptime over the past five years.

Security Concerns: A 2024 GAO report identified the legacy systems as potential security vulnerabilities. The report noted that Windows 95 has not received security updates since 2001, creating theoretical attack vectors. However, the FAA stated that these systems operate on isolated networks with no internet connectivity.

Cost Estimates: The $1.2 billion modernization budget includes hardware replacement, software development, facility modifications, and controller training. The FAA projects ongoing maintenance savings of approximately $85 million annually once modernization is complete.

Workforce Impact: The agency plans to retrain approximately 2,400 controllers and technical staff on new systems. Training programs will begin in fiscal year 2027, with each controller receiving an estimated 40 hours of instruction.

The modernization effort offers several benefits:

Enhanced Security Posture: Replacing systems that cannot receive security updates eliminates a category of potential vulnerabilities, even if current risk is mitigated by network isolation.

Improved Maintainability: Modern systems will use standard components and software, reducing the specialized expertise required for maintenance and the risk of parts obsolescence.

Operational Efficiency: Network-connected systems will enable faster data transfer between facilities, potentially reducing delays in flight plan amendments and weather updates.

Workforce Development: Training on modern systems will help the FAA attract and retain technical staff who may be reluctant to work with decades-old technology.

Figure 3: Privilege escalation from user to SYSTEM level

The transition also presents challenges:

Transition Risk: Replacing systems that have operated reliably for decades introduces the possibility of new failure modes. The FAA's parallel operation plan addresses this concern but adds complexity.

Cost Uncertainty: Large government IT modernization projects frequently exceed initial budget estimates. The $1.2 billion figure represents current projections and may increase.

Training Burden: Retraining thousands of controllers while maintaining normal operations will strain FAA resources and may temporarily reduce operational flexibility.

Vendor Dependence: Modern systems may create new dependencies on commercial software vendors, potentially complicating long-term maintenance and security.

Air traffic control systems integrate multiple technology layers to track aircraft, manage flight plans, and coordinate between facilities. The systems targeted for replacement serve specific functions within this broader infrastructure.

TRACON facilities handle aircraft approaching and departing airports, typically within a 30-50 mile radius. The Windows 95 workstations at these facilities run specialized software that processes radar data and displays aircraft positions to controllers. The software was developed specifically for the FAA and has been maintained through custom patches rather than standard Windows updates.

Floppy disk data transfer occurs at facilities where legacy systems predate network infrastructure. Controllers physically carry disks between workstations to transfer flight plan data, weather information, and system configuration updates. While slow by modern standards, this process has proven reliable and eliminates certain categories of network-based failures.

Technical context (optional): The FAA's air traffic control infrastructure includes multiple system generations, from 1960s-era mainframes (largely replaced) to modern networked systems. The Windows 95 workstations represent a middle generation that was state-of-the-art at deployment but has since been overtaken by technology evolution.

The FAA's announcement reflects broader challenges facing critical infrastructure operators worldwide. Many essential systems, from power grids to water treatment facilities, rely on technology that has exceeded its intended lifespan but continues to function.

The aviation sector's approach to legacy technology modernization will likely influence other infrastructure operators. The FAA's phased transition plan, with its emphasis on parallel operations and extensive testing, provides a template for managing similar transitions in other domains.

The announcement also highlights tensions between operational reliability and technological currency. Systems that have operated successfully for decades may pose lower immediate risk than new systems with unknown failure modes, even if the legacy systems are theoretically more vulnerable.

For the aviation industry, the modernization effort signals continued investment in air traffic control infrastructure. Airlines and airports may need to adjust their own systems to interface with FAA upgrades as they are deployed.

Confirmed:

• Windows 95 workstations remain in use at 17 TRACON facilities
• Floppy disk data transfer continues at facilities lacking network connectivity
• The FAA has committed to a 2030 completion target for legacy system retirement
• The estimated budget is $1.2 billion
• Parallel operations will continue during the transition

Unclear:

• Specific facilities affected (the FAA has not published a complete list)
• Detailed technical specifications of replacement systems
• How the FAA will handle potential budget overruns
• Whether the 2030 timeline is achievable given historical IT project delays
• Impact on air traffic control capacity during the transition period

Several indicators will reveal the progress and challenges of the FAA's modernization effort:

• Congressional appropriations for fiscal year 2026 and beyond
• Selection of vendors for replacement systems
• Results from pilot facility deployments in fiscal year 2027
• GAO follow-up reports on modernization progress
• Controller union statements regarding training and transition concerns
• Any incidents or near-misses attributed to legacy or transitional systems

The FAA's quarterly NextGen progress reports will provide ongoing visibility into the modernization timeline. Aviation industry groups have indicated they will monitor the transition closely and advocate for adequate funding.

1. Ars Technica - FAA Legacy Systems (June 26, 2025): https://arstechnica.com/tech-policy/2025/06/faa-finally-plans-to-retire-windows-95-floppy-disks-from-air-traffic-control/
2. FAA NextGen Program Office: https://www.faa.gov/nextgen
3. GAO Report on FAA IT Modernization (GAO-25-106847): https://www.gao.gov/products/gao-25-106847