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Pharmaceutical Warehouse Floor – 2 years later and still going strong

March 14, 2019

In the world of coatings, its not always good enough to worry about the here and now. Many products can look great after you apply them. The real test is how they stand up after months and years of hard use. Factory and warehouse floors often take some of the hardest wear and tear in the industry. From forklifts to jib cranes, the machinery moves thousands of pounds daily and the coatings used on the floor needs to be durable and strong to withstand the pressure.

Pumpcoat ~ PCI Contractors has a customer in the pharmaceutical manufacturing industry. Their large warehouse floors required a tough concrete hardener and sealer. Approximately 7000 square feet needed to be prepped, ground and coated. Pumpcoat used diamond grinders to prep the floor for coating. Using Consolideck Concrete Sealing System, a first coat of sealer/hardener & densifier was applied. This product penetrates the concrete pores and hydrates them, thereby creating a dust-proof prime coat that does not contain high amounts of potassium or sodium salts. The Top coat was done with PolishGuard protective sealer. It is highly durable, and creates a high-gloss protective finish that is stain and chemically resistant. This is optimal for these type of floors in case of accidental spills from moving products around.

Pumpcoat worked with the customer to do the coating in two mobilizations so that their warehouse equipment could be moved around and downtime would be minimal rather than taking the whole floor offline for the duration of the work. Pumpcoat’s expertise in application, along with this superior coating system allowed for a beautifully finished floor that was robust in durability and strength. Even after two years from coating, this warehouse floor is still in great condition despite being heavily used on a daily basis for equipment ranging from 5,000 to 40,000 pounds. If you are experiencing issues with your flooring substrate or coating failing, call Pumpcoat ~ PCI Contractors today so we can help solve your problems.

 

Custom built Containments by Pumpcoat

April 27, 2018

Tank Containments are probably given minimal thought on a regular basis, but when a tank emergency occurs, they are essential at preventing harmful chemicals from spreading throughout the plant. From a health and safety perspective, having a containment you can depend on in times of emergency is one less thing a Maintenance team has to worry about.

Pumpcoat/PCI Specialists are skilled in building and coating containments and basins for facilities. A recent build was for a power generation customer in New York. They had an Ammonia Tank being installed that needed a containment. PCI excavated the site, created footings, incorporated the rebar into the wall and floor and poured concrete. Berm walls were built up to the customer’s specifications and the entire containment was coated with epoxy specifically designed to withstand aggressive corrosive environments. Pumpcoat worked within the customer’s schedule to assure minimal disruption to their schedule. Pumpcoat can also supply tanks for your chemical needs.

Are your containments in need of a safety upgrade to give you peace of mind? Call Pumpcoat today at 508-540-5878.

Scarifying, Grinding and Mastic Removal – Floor Prep for Construction by Pumpcoat

July 28, 2017

Proper Floor preparation is critical in getting the job done successfully. Pumpcoat has assisted construction companies and other customers with this process that often gets overlooked or rushed through. Our workers have experience to be able to prep concrete floors to prepare them for seal coating, new epoxy coatings or other floor treatments.

One of our Construction company customers had a client with a Frankenstein-like floor. This floor had had a couple of old coatings layered on, as well as having been repaired in a few areas so the floor level was different. Additionally, the site was near a river, so the Environmental codes were strict about no liquid emissions draining into it. Pumpcoat stepped up to the challenge. Old repaired areas were chipped off and ground down. The old coatings were removed. The entire floor was scarified down to an 1/8” profile. It was powerwashed in stages and the liquid vacuumed to prevent any run-off into the drains. The surface was allowed to dry to SSD (Saturated Surface Dry – No standing water) and prepped for a waterproofing treatment which was applied a few weeks later.

Grinding concrete uses large machines like Shot blasters or diamond grinders to scarify the concrete to prepare the floors to have the next layer of coating adhere properly. Pumpcoat’s workers have ground thousands of square feet of concrete floors to prep them for our affiliated Construction companies to come in and do their floor treatments. Pumpcoat can also profile the concrete to whatever Surface Profile is needed for the up and coming floor treatment.

Sometimes a previous floor will have been in place when a building is being renovated. Old tile flooring or the messy adhesive remnants known as Mastic will need to be removed before the new flooring can be put down. Pumpcoat’s experience in dealing with pulling up tile or stubborn mastic removal leaves the headaches to us and leaves a clean prepared floor at the end of the day.

So Whatever the prep work needed, Pumpcoat has the knowledge and skill to complete this key step of floor preparation for the project to be successful.

Pumpcoat does repairs & coating for Fuel Oil Tank foundations

June 26, 2017

One of Pumpcoat/PCI Contractor’s Gas Turbine Power Generation customers have some ageing Concrete Tanks with moats (gravel based containments) that house fuel oil, and were showing a lot of cracking and spalling.   PCI was chosen to perform rehabilitation and coating on these surfaces.

The two tanks measure approximately 100 foot diameter each, the bases at 116 feet.  Pumpcoat used a system of Sika products to repair the spalling and cracks, per customer specs. The cracks were hand prepped  by removing cracked paint,  notching or V-cutting them, and cleaned to remove any oils or loose debris.  The bases and moat walls were power-washed.

Sika flex was injected into the smaller cracks, allowed to cure. Larger cracks were filled with SikaTop Cementitious Repair Mortar.  The cured cracks were then sealed with SikaProof Seal. Sika Armatec was applied on any exposed rebar. A Corrosion Control additive was mixed into the repair mortar where necessary to prevent further corrosion.  Resto-crete was used for rebuilding larger areas where concrete had worn away.    Finally,  Pumpcoat epoxy coated the bases in a waterproof epoxy system.   The gravel in the moat areas was backfilled with fresh gravel, and the project was complete.  The customer was very pleased with the final result, and the tank bases had been brought up to Environmental code.

Cost Effective Solution for Concrete Floor Crack Repair

November 15, 2016

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.

Large Municipal Pump Repair by Pumpcoat

September 21, 2016

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.

Refurbishing Pump & Motor Bases

May 18, 2016

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.

corroded pump base-2

Before- Pump base corroded from salt water

epoxy base-rsz-wording

After- Base refurbed with paste grade epoxy, then top-coated with epoxy to match pump (picture -sample from manf.)

 

Neptune Research

Let us solve all your pump & coating problems!

Pumpcoat

Let us solve all your pump & coating problems!

Neptune Research

Let us solve all your pump & coating problems!

Pumpcoat

Let us solve all your pump & coating problems!

Neptune Research

Let us solve all your pump & coating problems!

Pumpcoat

Let us solve all your pump & coating problems!

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