Cracks in concrete floors, drives or parking lots are a common problem for building owners or property managers. Either constant use from heavy machinery, or the freezing and thawing cycle in the cold months causes contraction and separation of the concrete and thus cracking. It can be an expensive proposition to re-do the entire area. Pumpcoat/PCI Contractors have products that help property managers stay on top of unsightly and unsafe cracks, that are more cost efficient than an entire floor resurfacing.
Recently one of Pumpcoat/PCI’s factory customers had just such a problem with lots of cracks in a large concrete floor in one of their warehouses. This area saw lots of heavy machinery traffic like forklifts and loaders. They wanted a more economical fix than resurfacing the entire floor.
PCI was called for the repair work. We worked within the customer’s schedule to allow for the least amount of downtime, and started by prepping and cleaning the cracked flooring areas from dirt and loose debris. Some grinding and feathering around the cracks’ edges were done to allow for best adhesion of the repair material. PCI used Arcor Spraythane to apply to the cracks. Spraythane is a high elongation, elastomeric hybridized epoxy-urethane material. Its unique properties allow for movement of the concrete as it expands and compresses with the cold and prevents further fracturing of the cracks. PCI Contractors were able to repair the cracks in their customer’s warehouse floor and ease their mind that the costs wouldn’t be exorbitant. If you are experiencing cracking or other concrete issues in your floors, please call Pumpcoat/PCI Contractors today for economical repair solutions.
Sometimes size does matter. A Wastewater treatment department from the Boston South Shore area has a very large Diesel Lagoon pump that serves the function of de-watering when the streets near the shore got flooded. This Hydraflo pump has a flow rate of 42 inches and 50,000 gpm, this pump was no lightweight. Seeing much of the problems faced by Louisiana as of late, one can appreciate the need to have pumps in that setting maintained in good working order. Pumpcoat had done some minor repairs to the pump over the past few years, but it was time for a major overhaul.
The pump was taken out of service and brought to Pumpcoat’s shop. From there, the pump was grit-blasted, disassembled and inspected. Some areas of the casing that had worn received weld patches, and a thick film ceramic epoxy coating was applied to the entire housing. The hydraulic motor driver was then rebuilt by our motor specialist. The pumping elements were inspected for repair. The impeller had build-up which was removed. The impeller bore was severely pitted, so received epoxy repairs and then was re-honed for size. It received a new mechanical seal, gaskets and thrust bearings. Certain parts like the shaft were within spec, so polished for re-use.
Once all the elements were repaired, the pump and motor were re-assembled and tested, then returned to the customer’s facility and re-installed. Pumpcoat was able to rebuild the pump at a fraction of the cost of a new pump. The pump was back in good working order and the customer was happy.
A Power Plant customer had several pump & motor bases that had extreme corrosion due to the aggressive salt water environment they were in. Many of their pumps & motors were older units, and new bases were not available either because the factory no longer made parts for the pumps, or the ones that did would require a lot of machining and changes to get them to fit correctly. Additionally, they were rather costly. Pumpcoat did a survey of the units, and put together a refurbishment program for their pump bases.
Working on site according to our customer’s schedule, Pumpcoat~PCI Contractors protected the motor and pump by using plastic sheeting along with taping off the bearing housings and motor air vents. Containment and Dust collection were provided, and the coupling guards were removed and grit blasted and coated at our shop. Each base was prepared by needle gun and grinding, then wiped down with a special solvent that removes excess salt. After allowing to air dry, Pumpcoat~PCI coated each base plate with a coating system designed to protect from future corrosion. The top coat color was matched to the pump as needed. Some units were worse off, so Pumpcoat replaced welded nuts, damaged bolts, and added support ribs to the frames that needed them. A few of the pumps that needed maintenance were brought to our shop and repaired – new shaft sleeves, gaskets, oil seals and pump bearings were replaced, and the pumps were reinstalled at the customer’s. In less than a week, the pumps were back in service, looking and working good as new. The epoxy coating system would continue to protect the pump bases from the aggressive environment for quite awhile. Our customer was happy with the work and the cost-savings to their budget over not having to purchase brand new bases.
Pumpcoat~ PCI Contractors has been in business for 17 years, providing high quality service to customers in power generation, industrial, commercial, property maintenance and other industries. Along the way, we’ve acquired a wide variety of abilities.
Good service and satisfaction have always been cornerstone values at PCI. Sometimes we find our customers will need something done that is not in our skill set. Over the years, we have built up a “Vendornet” (Vendor network). PCI has developed good relationships with other qualified and reliable companies that have complementary skills to our own that we can subcontract and get the job done.
An example is a large floor we did for an Industrial customer. Pumpcoat utilized its Vendornet to subcontract a company that routinely did large area blasting. Using larger machines and additional manpower, the blasting work was done quickly. Supervisory Personnel from PCI ran the job to make sure all the customer’s Environmental, Health and Safety specifications were adhered to. Once the blasting was complete, PCI workers applied the coating. From the customer’s perspective, the job was seamless. One Purchase Order to manage, and the quality and safety was assured by Pumpcoat~PCI Contractors
Another example is a cooling tower repair we did for a manufacturing customer. The pans and some other frame parts were rotted through and beyond salvaging. Pumpcoat went through its Vendornet and used a local company that fabricates metal parts. We had new pans and beams made up with a quick turnaround. Pumpcoat installed the newly fabricated pieces, coated the everything for future corrosion resistance. The job was completed in a timely fashion and the customer was pleased with the quality of work.
In a time where good customer service has been trimmed from the budget, Pumpcoat~PCI Contractors makes sure that its customers are valued, and their satisfaction is our priority. Through its Vendornet, Pumpcoat~PCI can extend its services and keep its customers happy.
Too Big, Too Little, Just right – Pumpcoat’s Coating Experience helps solve a customer’s Waterproofing problems
A lamentable issue in the construction industry is that often companies will be too large and streamlined in a trade to be able to take care of all of a customer’s needs, or the company will be too small to have the manpower and resources to adequately take care of all the aspects of a customer’s project. When a Building Maintenance company who services many large Parking garages in the Boston area found itself needing to take care of replacing the concrete and waterproofing some areas in one of their properties, They called Pumpcoat.
Pumpcoat ~ PCI Contractors diversity has made us a ‘go-to’ company for problem-solving. On this particular project, our customer was experiencing a lot of cracked concrete originating in the expansion joints of the pedestrian ways of one of the garages, and also at the building’s entrance-way (front Apron). Additionally, they needed a waterproof and durable coating system for these areas. Because the building was extremely busy, the areas that needed coating could not be taken out of service very long, both for the safety of the pedestrians, and the flow of traffic/potential loss of revenue for the building’s occupants. A coating with a quick cure time was needed. Pumpcoat ~ PCI Contractors’ field service team did a new concrete pour over the previously removed substrate for the Building’s front entrance area. They then researched for the most ideal coating for this application and ended up choosing the Tremco Vulkem ‘Extreme Wearing System’ (EWS ) Coating. This coating has been designed to have extreme abrasion resistance, ‘tenacious’ adhesion, and cures quick enough so that it can be walked on an hour after finishing the coating. It is versatile enough so that it can be applied even in freezing temperatures, which allows for projects to continue in the colder months. The Vulkem EWS also protects concrete from the damaging effects of vehicle fluids such as gasoline, oils and antifreeze, and de-icing salts and chlorides as might be spread on roadways during the winter.
There are four coats to the Vulkem EWS system: a Primer, Base-coat Waterproof Membrane, a Wear-coat, and then a top coat. The system retains its integrity and prevents water migration between itself and the substrate. The wear-coat has an abundance of aggregate so that it maintains high impact, abrasive, and chemical resistance. Each coat cures in an hour or less so the next coat is able to be applied. Pumpcoat~PCI Contractors applied the entire system in less than a day which was scheduled with respect to the customer’s least busy time, so they had minimum interruption to their business. Pumpcoat ~ PCI Contractors are now in their 18th year of service.Our experience continues to help find solutions to their customers problems.
One of Pumpcoat/PCI Contractor’s Power Generation customers in Connecticut recently built a new storeroom. Their previous one was no longer large enough. Once the new structure was built, there were a few components that PCI Contractors was able to lend its expertise to completing it to spec. The flooring the customer required was a non-skid floor that mitigated moisture. PCI installed a new epoxy flooring system, of approximately 1700 square feet. The first coat was of Duraglaze MVP primer. Duraglaze MVP can reduce moisture levels up t o 99 %. It also provides an excellent basecoat. The top-coat applied was Duraflex Armor Top pigmented gloss coat. This is a protective Urethane coating – it is specially formulated for high traffic areas to protect against chemicals and wear. By broadcasting Aluminum Oxide grit into the coating, it creates a non-skid surface that is safer for personnel to walk on. PCI applied line-striping the floor to demarcate the aisles, forklift lanes, and other safety markings. Also called for was a concrete pad of approximately 400 feet which PCI poured in an area of the warehouse. This pad created an area where machinery could move around on without worrying too much about cracking and chipping.
The next phase of the new warehouse was moving the steel shelving and cabinets from the old storeroom to the new one. PCI Contractors subcontracted a local company with experience in that area. They transported the shelving, cabinets, mezzanine system and set it up in the new storeroom, making sure that it was done to safety code and replacing any lost parts.
Finally, PCI provided water drainage and waterproofing to the Exterior wall of the new storeroom. This wall in particular was noted to be in a high risk area for standing water build-up and possible seepage. Approximately 2 feet deep trenching was dug 50 feet along the exterior of wall and backfilled at a slope to promote better drainage. After power-washing the wall, A BASF Concrete Waterproof coating was applied, and corrugated piping put along it for drainage of rainwater.
For a multitasking project like the new storeroom building, Pumpcoat/PCI Contractor’s years of experience and adherence to safety and quality can help our customers get it completed on time and without the headaches.
Flat roofs that are found at plants, factories and other industrial buildings will almost inevitably end up with leaks at some point in their history. Pumpcoat~PCI Contractors gets several calls for leaks, roof repairs and coatings each season.
Areas on roofs where something sticks up from the roof – like piping, vents, exhaust fans, etc. are called penetrations. Anywhere there is a penetration, the area is prone to leakage. Penetrations are surrounded by metal strips and caulking, called flashing, that acts as weatherproofing. Over time, flashing and caulking can break down, allowing water to flow down through the roof coating and cause damage.
Although leaks may seem minor, they can lead to much bigger problems like mold, rust & corrosion, water damage, rotting of walls and ceilings among other issues. Also, water can damage expensive equipment in a factory or power facility. Pumpcoat~PCI field service professionals are experienced in finding the source of the leaks and repairing them.
Pumpcoat-PCI received a call from one of our power generation customers in Western Massachusetts. They were experiencing several leaks of unknown origin when the snow melted. After careful inspection, PCI’s service professionals were able to pinpoint the sources of the leaks. They replaced the flashing & caulking around the penetrations. The entire roof was then coated with a two-part EPDM rubber membrane called CIM 1000. This product forms a seamless, waterproof, elastomeric membrane. It meets tough VOC requirements, and is available both in black (for absorbing the sun’s rays) and white (for repelling them). This can help with defraying the building’s heating or cooling costs depending upon the need of the facility, which makes it a very “environmentally friendly” choice for coatings. The CIM 1000 material combines the flexibility of a urethane coating with the water impermeability of asphalt that lasts for several years. The PCI field service team were able to repair the leaks and coat the roof in a quick and efficient manner without disruption to the customer’s schedule. The facility manager was very satisfied with the job, which not only saved him money from damage to the building and equipment, but also resulted in an energy savings for the building. If you are experiencing leaks or are looking for a roof coating that is durable and cost-efficient, call Pumpcoat~PCIContractors at 508-540-5878.