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Multi-step Storeroom project: new non-skid flooring, wall waterproofing and more

September 3, 2015

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.

Storeroom floor - Before

Storeroom floor – Before

Storeroom floor - Before

Storeroom floor – Before

Storeroom floor - AFter

Storeroom floor – After – Non-skid, water mitigating epoxy flooring

Pumpcoat- application of new epoxy flooring for a storeroom

Storeroom floor – After – non-skid, water mitgating epoxy floor

End of Winter Could Mean Leaky Roofs and the need for Repairs and Coatings

March 18, 2015

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 - roof coating

Roof coating at power plant, used an EPDM Elastomeric Membrane that is black to absorb the sun’s rays and save in energy efficiency.

Pumpcoat-roof coating

note the repaired flashing around the penetrations. When flashing & caulking is old and begins to break down is when leaks can begin.

Custom Sheet Metal Fabrication – One service we take care of for seamless facility maintenance

February 10, 2015

Unlike some service companies who are very two dimensional and have issues difficult for them to overcome when they come across a problem during the course of their work,   Pumpcoat ~ PCI Contractors doesn’t balk when it runs into some complications on the job.  Here are a few examples of Sheet Metal Fabrication that we have been able to provide for our customers:

Air Park Building Doors:  Last Fall, a bad storm had come through the area and damaged one of the metal buildings at a local airpark. The doors had been nearly torn off and were badly mangled.   PCI sent a Field Service Professional out soon after and took the appropriate measurements for new doors. Through one of our affiliate machine shops, new custom doors were cut, and PCI installed them with a very quick turnaround, getting the building back in working order.

Cooling Tower Distribution Trays: PCI was in the process of a Cooling Tower rebuild, when it was found that the distribution trays (large pans underneath the towers that hold the cooling water) were rusted out. They were too far gone to be salvageable with our normal means of epoxy rebuild material. Our Field Service team took measurements and we had new trays made to order in a short amount of time. The trays were given an epoxy top-coat to help withstand future rust and erosion, then installed into the tower. The total Cooling Tower job was still finished on time, with a very minimal increase in the original estimate.

Cooling Tower Louvers: Another Cooling Tower PCI was repairing had severe corrosion issues with the air intake louvers on front.   Our Field Service Team measured and diagramed a set of replacement louvers which were then fabricated at our affiliate shop.  They were installed when the tower was put back together and functioned perfectly. The new louvers added efficiency to Cooling Tower as a whole.

Jet Enclosures: PCI Contractors were servicing a Power Generation’s Jet Enclosures. This is a small unmanned facility with several buildings that housed jet turbines and equipment used to produce additional power for the grid. Many of these buildings had begun to show external wear from the environment.  A few of the buildings sported metal awnings above the doors as additional protection from the elements.  The awnings had begun to rust severely.  PCI measured and fabricated new awnings on site as  part of the total maintenance package provided to the customer for that facility.

Pumpcoat ~ PCI Contractors has the ability to provide a full complement of services relating to facility maintenance. From metal issues to coatings to mechanical equipment like cooling towers or heat exchangers, PCI’s service people are well versed in solving problems.

Pumpcoat - Jet Enclosure - Door Awning from sheet metal

On site sheet metal fabrication of an Awning

Pumpcoat - Cooling Tower Air Intake Louvers: Before

Cooling Tower Air Intake Louvers: Before ~ note severe rust and corrosion. (prevents the louvers from functioning efficiently for air intake).

Pumpcoat - Cooling Tower Air Intake Louvers: After

Cooling Tower Air intake Louvers. – New Louvers fabricated from sheet metal not only looks better but increases the efficiency of the unit.

Finding the right coating for a Food Prep Cold Room floor

November 20, 2014

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.

cold room floor coating-rsz

October Scariness – Pumpcoat’s Deep Pit Shaft Repair

October 20, 2014

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.

hydroturbine-with person          hydropower-plant-parts-words

It’s Fall! An excellent time for Cooling Tower Repairs

October 3, 2014

Cooling Towers play an integral part of the Air Conditioning Systems for many buildings and plants. From late spring to early fall, they are in constant use removing process heat to help keep the inside environment comfortable.

Fall  is the perfect time to catch up on repairs on these hard working units when they finally get a break from being in-service.  Pumpcoat ~ PCI Contractors can help with advising a regular maintenance schedule or doing repairs to many of the internal components. Repair your Tower will increase efficiency of the unit which amounts to saving money during the next season.

Ideally, Cooling towers will receive regular maintenance such as water treatment to prevent build-up of harmful bacteria, scale, algae and corrosion; cleaning of the spray nozzles to prevent clogs;  debris removal from suction screens;  inspections of the pump and motor  & fan to ensure they are operating properly,  and other tasks.  But sometimes, even with maintenance and the best of intentions, a Cooling tower will need repairs. Here’s how Pumpcoat ~ PCI can help.

Cooling Tower Fan Blade Repair

Fan blades wear down, especially on the leading edges, and experience corrosion and pitting.  Once they are worn, it causes an unevenness in the rotations, forcing the machine to lose efficiency and wear to the other components.   Pumpcoat ~ PCI Contractors can repair these blades.    An epoxy system of Arcor – specially designed for rebuilding metals in immersion service.  They are suited for abrasion and corrosion protection and are environmentally friendly in that they have no VOC’s and are solvent free.

The Fan blades will be hand tool prepped,  pitted & corroded areas are rebuilt with a paste grade epoxy.  A top coat of epoxy produces a tough, resistant coating.  We take care that the epoxy is evenly applied so that the end result will be the fan blades have an even weight of coating


Fan Blade – wear, corrosion & pitting esp. on leading edge (

Cooling tower fan blades

Cooling Tower Fan (

 Cooling Tower Basins

The basins or pans at the bottom often see a lot of rust and corrosion, many times due to standing water.   When the water fails to circulate, there is risk of bacteria build-up such as legionella that can cause Legionnaires disease.    Pumpcoat ~  PCI Contractors can blast and coat basins, or even fabricate new ones if the damage is too far gone on the existing pans.        The basins are cleaned, removing scale and build-up,  blasted to remove the rust and corrosion.  Then Arcor paste grade epoxy is used to fill in the pitting and build -up any areas that have worn.    A top coat of immersion grade epoxy gives the Cooling Tower basin a life extension.  Epoxy also has some innate anti-fouling properties, so can resists future build-up.


Cooling Tower Basin – Before (


Cooling Tower Basin – After Coating (

 Fill & Drift Eliminator Replacement

Cooling Tower fill is essentially large plastic corrugated sheets that increase the surface area for the water that runs through the tower.  The increased surface area helps cool the water down more effectively.   Drift Eliminators work with the fill, limiting the amount of water that escapes from the system via evaporation or emission with the exhaust air.  Fill & Drift Eliminators, like the other Tower components, can get brittle, dirty and bacteria ridden over time after being in constant contact with water.  One of the services  Pumpcoat ~PCI Contractors can help with when rebuilding a Tower is replacing the these items, which removes the dirt and bacteria with the old fill and eliminators and increases the efficiency of the unit overall.


Example of Fill

Structural Support and Welding

The framework of the Tower, usually made of structural steel, is also at risk for rust and corrosion.   Being exposed to the elements as most of the towers are outside on rooftops,   -wind, rain, cold, ice & snow can cause damage over time to the towers structure. Pumpcoat ~ PCI  can weld repair or epoxy patch structural steel to repair and reinforce it. If there is considerable damage, our metal fabrication for making replacement parts such as exterior louvers will do the trick.


Louver/Frame – Before (


New Louver Fabrication – replacements – side view (


New Louvers/frame fabrication replacement – Front View (

Don’t delay! 

For repairs or a total rebuild,  Pumpcoat ~ PCI can service your tower. Keep in mind regular maintenance and repairs to a Cooling Tower can improve efficiency, save money and energy and provide a healthier environment for all.

Benefits of an Epoxy floor with Cove base

August 22, 2014
Pumpcoat - PCI Contractors: Epoxy floor with cove base-before & after

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.


Pumpcoat – tile floor before (grinding begun as prep for the cove base)


Pumpcoat – tile floor – “before” picture – note the discoloration of the grout indicating that dirt and bacteria have settled into the pitting


Pumpcoat – “Before” lowest row of wall tiles removed as prep for the cove base being added after.



Pumpcoat – “After” Duraquartz blend floor with cove base – Aesthetically pleasing, seamless epoxy. Check out those corners!


Pumpcoat – “After” Duraquartz blend floor with cove base – this will be much easier to maintain & clean


Pumpcoat – “After” Duraquartz blend floor with cove base. – Impact, heat & chemical resistant!

NRI - Neptune Research Inc

Let us solve all your pump & coating problems!


Let us solve all your pump & coating problems!

NRI - Neptune Research Inc

Let us solve all your pump & coating problems!


Let us solve all your pump & coating problems!

NRI - Neptune Research Inc

Let us solve all your pump & coating problems!


Let us solve all your pump & coating problems!


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