Pumpcoat – PCI Contractors has done many epoxy floors over the years. We have become the “go-to” company for coatings on floors and equipment. Recently we installed some epoxy flooring for a large University in Boston. It was applied in their dormitory bathrooms. In addition to the normal Duraflex flooring system, we added a 4 inch cove base.
The old floor in the bathroom was tile. Although still structurally sound, the tile and grout was old and had begun to stain and wear making it look continuously grungy. When grout begins to wear down, the pitting creates a prime place for bacteria to grow, so it becomes harder to keep clean and sanitize. The Epoxy floor was installed directly onto the tile using it as a substrate. Prep included acetone wiping, dustless diamond grinding, grit blasting of the corners and edges. The toilets and most other plumbing fixtures were removed or taped off prior to the coating.
Duraflex Duraquartz is a three part epoxy system. The initial coat was poured on and also served to level the old tile floor. The grinding as part of the prep process increased the surface area of the substrate and allowed the tile to adhere to the epoxy layer. The mid coat was Dura-glaze. It was troweled down and then a quartz colored blend was broadcast throughout which is what give the unique color and dimension to the finished floor. After the curing time, two layers of Duraflex Ultra clear top coat were added. Then a 4 inch cove was created around the walls.
A cove base is a continuation of the epoxy floor that runs up the wall. Usually coves are anywhere from 2-4 inches in height. Coves are beneficial for a few reasons. Just like the epoxy floor, they create an easy to clean, seamless surface. Especially in a lavatory where there is a good amount of water and moisture, a regular baseboard or wallboard would easily succumb to mildew and mold. Epoxy floors and coves are also chemically resistant and durable. Where previously, the grout from the tile floor had begun to break down and pit, the epoxy stands up to traditional cleaners and repeated washings. Having a cove also means not having a crack between where the floor ends and the wall begins, which means less space for bacteria or mildew to form since the in-between areas like cracks are hard to clean. Finally, the cove base is aesthetically pleasing since there is no ‘visual break’ in the floor to wall surface.
Epoxy Coatings as applied by Pumpcoat – PCI Contractors can improve safety by creating a slip resistant flooring solution. In addition to being impact, heat and fire resistant, epoxy floors and cove bases are environmentally friendly and cost efficient choice. They are a terrific ‘Green’ alternative. Many epoxies we use have low or no VOC’s. Their ease of care requires fewer harsh chemicals for the environment too.
Give Pumpcoat a call for help with solutions to your flooring problems.
A Contractor had called Pumpcoat regarding our Specialty Coatings. We have coatings on parts installed in Ash Systems and other highly abrasive applications at Power plants throughout New England. He wanted to know if we had something that would be able to help one of their clients out. They were a Lab that had gate valves that were seeing high wear and corrosion rates in service. The Service the valve was in was high temperature vacuum service : 90o Celsius (approx. 194o Fahrenheit) and had HCL and Nano particulate in the gas that the valve came into contact with.
Initially we planned to do the entire coating with Arcor S-20, a high functionality epoxy Novolac designed particularly as a protective coating for metals in highly aggressive environments. After speaking more to the customer, our Lead technical engineer decided to go with a Hastelloy Spray coating with a top coat of S-20 so the wear rate would decrease significantly.
Hastelloy is actually a coating made up of powdered metal, that when spray-applied in a special chamber, adheres to the item. Hastelloy contains nickel, molybdenum and chromium and offers tremendous corrosive resistance and high temperature strength. It can be found in applications such as seals, springs, valves and even aerospace parts. The top coat of S-20 offers an additional layer of corrosive resistance.
By Spraying Hastelloy on 316 Stainless Steel, you can achieve corrosion resistance without the expense of a solid Hastelloy part
The Gate valve delivered to Pumpcoat’s shop, disassembled, and the valve part underwent the Hastelloy spray coating process. Pumpcoat then coated the parts with the S-20, did a Quality control check, and reassembled the valve for delivery back to the customer. The entire process took a couple weeks. The end result was a problem solved for our customer. If you have mechanical parts such as valves, seals or others that wear out quickly due to highly corrosive environments, call Pumpcoat at 508-540-5878 to see how we can help.
Pre-job safety orientation is nothing new in the world of contracting but when it involves working at a Nuclear Facility, it goes to a whole new level. Pumpcoat had gotten the project of coating the interior of two water tanks at a Nuclear Power plant in Maryland. Prior to the project beginning, our field service team traveled to their site for
the classes. It was 2 weeks of several hours each day of coursework for PCI’s workers, in order to learn the ins and outs of safety and what was allowed on a Nuclear site. Our office staff sent the paperwork regarding physicals, fit testing, background checks, PCI’s Safety Program and other protocol to their safety officer. Lists of tools and equipment had to be approved of before being allowed on site. The actual type of grit and epoxy also had to be pre-approved, as did the type of sandblasting suit and other PPE.
In the end, PCI Contractors passed the muster and were able to mobilize to site to work on the tanks.
During the project, each worker needed to sign in and go through a daily ‘tailgate’ meeting. Tailgate meetings are ones that PCI does as part of every service project, The workers discuss the possible safety issues, any site hazards and what is to be accomplished during the course of the day. They make sure their safety gear is properly functioning, etc. At the Nuclear facility, there were additional protocol, such as signing in and out of the work area, accounting for the tools that were brought into the area, and other things.
The tanks were potable Fire and Water storage tanks. As part of the project scope, PCI arranged for portable tanks to be brought in to store water. (The tanks that were being coated was the facility’s normal fire emergency supply). Working on one tank at a time, Each tank was grit blasted. Parts of the tanks interior were treated for corrosion with Arcor’s EE-95 paste grade material. Larger holes were plugged and blended into the epoxy for seamlessness. Top coats were applied of Arcor S-20, an NSF epoxy coating, which is approved for potable water. Spent grit was removed and disposed of in an environmentally aware manner. PCI Contractors were able to do the job efficiently and to the customer’s satisfaction. PCI Contractors is now in its 17th year of servicing customers. We are problem solvers and get the job done.
A Pumpcoat customer had an issue with cracked concrete flooring and out-of-date safety line striping. As a factory that manufactured roofing materials, their eye was on keeping their factory up-to-code and safe for their employees. They called Pumpcoat to help them achieve that goal.
Pumpcoat/PCI Contractors came in and did a site assessment. A section-by-section plan was created to remove the old lines, repair the spalling and cracked areas around their concrete floor, and lay down new epoxy Safety lineage, hazard notations and a top coat sealer.
Over the course of two months, Pumpcoat/PCI made several mobilizations and worked around the factory’s production schedule as to provide minimum disruption.
Pumpcoat/PCI prepped the floor using Blast-trac shot blasters. It was ground in different areas, profiled and cleaned, removing the old striping in the process. The concrete cracks and spalling were repaired . New Safety lines were taped down and applied using Duraflex Epoxy Safety colors – Red, Green & Yellow. The different areas were demarcated with area specific Safety notices – in example: “Fork lift traffic only”
The lines were then top-coated with a clear epoxy sealer for increased durability. Areas of the Office, Operator line, Maintenance Warehouse, Fabrication shop & Loading dock were re-striped in this manner.
The customer was very satisfied with the end result. The new safety striping brought the factory within compliance of the Health & Safety code, as well as being able to keep the factory operational while the work was being done.
If you have problems with compliance due to obsolete signage, safety striping, handicapped accessibility or other issues, please call PCI Contracting for a consultation today. We can help!
Recently Pumpcoat did a repair of a large Fairbanks Morse pump for a Municipal Water Authority in Massachusetts. The pump was situated at their Wastewater Treatment Facility, with the impeller weighing in at 10,000 lbs (6 ft diameter x 4 ft. High), and the shaft was 2,700 lbs, (6 ft long x 13 inches wide).
Pumpcoat arranged shipment of these parts to our affiliate Machine Shop, where they underwent repairs to bring them back to OEM specifications. The shaft was repaired in various places by being welded, undercut and rebuilt with plasma spray to return it to spec. Pitting on the impeller was repaired by the same means. The impeller vanes were hand dressed and the impeller ring was polished. The shaft and impeller were then dynamically balanced. Once returned to the facility for the pump to be reassembled.
Pumpcoat has been a supplier for close to 2 decades for Municipal, Power Gen, Industrial, and other types of facilities. We supply a wide variety of pump parts: OEM, aftermarket, and we also have the ability for parts replication (for hard to source parts, or uncommon applications such as high corrosion environments).
These additional sources allow us to be very competitive with pricing.
We also have the ability to make impellers, shafts & shaft sleeves from samples in a wide variety of alloys. This can save our customers time and money, especially on parts that have a long lead time or are hard to source.
We can be very helpful with pumps common at Water or Wastewater plants like Allis Chalmers, Fairbanks Morse, Goulds or Gorman Rupp pumps. Our services like repairs to shafts, impellers or pump rebuilds can also be economical over purchasing new pumps. Call or email Yvonne or Mike at Pumpcoat to see how we can best help your facility save time and money.
A University in Boston had an alley area in the rear of one of their properties used for t rash & recycling storage for that block of buildings. The surrounding fencing had broken poles several places. The fencing itself had been damage. Silt and rubble had built up in the area, causing flooding after rain due to poor drainage and the build up around the foundation.
Some excessive trash spreading due to the compromised fencing had attracted pests. Masonry and the chimney base on the adjacent building had begun to wear and crack.
The area had become a safety and health hazard.
Prior to the work commencement, Dig-Safe was contacted or assessment of the power & utility lines in the area. The project was reviewed for any necessary work permits.
Excavate, Clean & Repair
PCI Contractor Specialists rose to the challenge of this multi-faceted project.
Working within the customer’s timeframe, PCI was able to do the following to solve the customer’s dilemma.
- Excess rubble and silt was removed to a depth of one foot.
- Larger, dense grade rock was put in its place to create a better drainage bed
- Wire mesh and rebar was installed as a framework for the cement
- A new concrete pad was poured at a slightly higher elevation. The pad was given a sloped apron to improve drainage
- Broken fence poles were replaced
- New fencing was installed in areas it had been damaged
- Fence doors were cut and welded to accommodate personnel
- Masonry repairs were done to the brick work in the chimney and building as needed
The customer was happy with the results of the project, PCI Contracting renewed the area and brought it within safety & health codes.
Do you have an area that could use updating for safety, health or aesthetics?
Call Yvonne or Mike at Pumpcoat ~ PCI Contracting today: 508-540-5878
A couple of months ago, a major Southern specialty contractor reached out to Pumpcoat. They had won a big job overhauling several kitchens in an assisted living complex and were looking for some help. The original kitchen hoods were made of steel and had rusted and corroded almost beyond repair. This caused a major health hazard and a crucial part of the job was bringing them up to code. The contractors initially felt that they needed to pull all the hoods and replace or “re-skin” the range hoods with new stainless steel. Both options were going to be prohibitively expensive, so there had to be a third choice.
Lucky for them (and us!), that is when they heard about the unique rebuilding qualities of Pumpcoat’s Arcor S-30 Epoxy. Arcor S-30 is a high functioning epoxy that contains Zinc Phosphate, which is great for inhibiting corrosion. Its high heat durability makes S-30 an excellent primer for things like range hoods, heat exchangers, pipes, and other heat conductors. It is also rated for immersion service so it can be used in water applications.
With S-30 as a primer, they then used our Arcor S-16 as a top coat, which is also perfect for high-heat applications, NSF-certified for portable water, and USDA-certified for incidental food contact. Along with the products, we provided them with a procedure for cleaning and applying the materials.
In the end, thanks to Acror S-30 and S-16 our clients coated a dozen kitchens all while reducing their project costs by 75%! Now that’s what we call a win-win!