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.
Pumpcoat ~ PCI contracting was contacted by a Construction contractor we have worked with before, regarding doing a floor in a Seafood Restaurant factory cold prep room. The floor needed to have the old coating removed, and a new one installed.
The room was approximately 600 square feet and contained freezer units and a prep area. There were a number of issues that made this project challenging. As this room was where food was stored and prepared, any coating we applied had to be safe for use around food. The temperature was regulated to 38 degrees F, which meant that the coating curing time would also be affected. Lastly, the factory needed to be able to get the room back in use fairly quickly, so that whatever product was chosen couldn’t have a long cure time.
Originally the spec called only for removing the old coating which would be done by shot-blasting. The customer then decided they wanted to seal the underlying concrete as well. Unfortunately, the condition of the concrete floor was not great. Once the old coating was removed, the original floor was found to be uneven and not aesthetically pleasing, so sealing it would have only added a clear moisture retardant coat to the floor, not fixed it as they were expecting. Pumpcoat ~PCI decided that instead of just a sealer, that an epoxy system would give the best result for what the customer expected for the end result. A few of the products considered were FDA approved, but the cure time was several days, which was too long. Some of the others would cure quickly, but not recommended for use around food. Ultimately the product that best fit the bill for the job was Duraflex Polycrete MDB, with TF top coat. This epoxy system is both NSF (potable water use approved) and FDA (Food & Drug administration) approved for use around food, and had a quick cure time, so the factory cold room would be back in service quickly.
Pumpcoat – PCI Contractors have used Duraflex products for many years with excellent results. There are several flooring systems available, to cover anything from the need to withstand aggressive chemical environments, to high temperatures, or thermal shock resistance. They are ideal in food processing plants or kitchens as they meet the stringent guidelines for those industries. They are also easy to clean, have high traction for increased safety, and come in a variety of colors and broadcast systems.
The project took one day for completion, and they were back in service by the next day. The construction contracting company was pleased because they were able to find a value-added service of floor prep and coat for their customer. The factory customer as happy because they had an updated floor that suited their needs with minimal down time. Pumpcoat ~PCI contracting worked with the customer to find the best coating to suit all their needs.
Have your own coating dilemma? Need advice on the right coating for the job? Call Pumpcoat today to discuss options and find the best coating for your needs 508-540-5878.
How Low can you go? Sometimes in the course of repair work, real life scariness comes into play. Deep holes, rushing water, confined spaces…. These repairs are not carried out by the faint of heart!
For the past few years, Pumpcoat ~ PCI Contractors have been called in to do repairs on various areas on a large shaft for a hydro-electric facility in Lowell, Mass. We repair a variety of shafts on a regular basis, but what makes this repair unique is that it several stories down in a pit that is regularly filled with rushing water. The shaft is part of the turbine system that generates the electricity for the plant. The entire piece of equipment goes down about 100 feet and has a series of wicket gates that open and close to control the flow of thousands of gallons of water from the dam through. Annually, the pit is de-watered for inspection and repair. Our workers went down approximately 60 feet (about 6 stories) into the pit via ladders and with safety harnesses. Although the water flow had been closed off, they could still hear the eerie sounds of the water many feet beneath them beyond the wicket gates. The walls around them in the pit were slick and slimy from being under water most of the time.
The repair required a first step of sand-blasting certain areas of the shaft. After which an NDE was carried out (NDE stands for Non-Destructive Examination) An NDE can include a variety of tasks such as Visual Examination, Ultrasonic testing, Liquid penetration and others. The Examination results show where there are corroded or pitted areas on the shaft that need repair. Once the NDE had been performed, the area is re-blasted and wiped clean. This brings the surface down to bare metal and removes any excess chips, rust or corrosion so the epoxy coating adheres to the surface.
PCI Workers then applied a coating of Arcor EE-11 Ceramic filled epoxy. This epoxy is perfectly suited for immersion service, and produces a tough, chemical resistant coating. The workers clean up and get back out of the pit, and once cured, the shaft is put back into service.
You hear stories from time to time in the news about repair workers getting hurt or killed on the job. So how does this happen, or rather, how can it be kept from happening?
Several safety measures are taken to prevent accidents on the job. In the case of the deep pit shaft repair, we had a Safety Rescue team onsite whose sole job was to have the equipment at the ready to extract a person if their safety harness failed or they ran into some other issue while at the bottom of the pit. Pumpcoat workers are Confined Space Trained, so they had the necessary skills and Personal Protective Equipment (PPE) for that particular job. PPE can include respirators, suits, gloves, masks, eye & ear protection. Other safety measures can that be used for different projects include air monitoring (for build-up of toxic gases) and air compressors with hoses to blow in fresh air to areas where work is being performed (like the bottom of a tank where other gasses can stagnate). If the equipment normally involves moving parts, a Lockout/Tagout is performed. (A safety protocol that can include a padlock inserted through to physically keep the equipment from being turned on, kind of like a chain through bicycle spokes). Most facilities have additional protocols set up so they know where all personnel & contractors are, and have extraction plans set up in case someone gets hurt. These are just some of the safety measures that are in place to prevent accidents and ensure worker safety.
The truth is that much of what the average person takes for granted – running water, electricity, heat and air-conditioning, etc. is handled by variety of infrastructure equipment that needs to be kept running and in good shape. The invisible hands of modern conveniences are really the culmination of many people who are responsible for keeping the pieces in working order. Some repairs can be scary but proper safety precautions can minimize the risks.
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.