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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.)

 

Pumpcoat’s Vendornet in Action – Blasting and Coating Large floors are a breeze

April 29, 2016
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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

January 8, 2016

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.

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Pumpcoat-PCI Contractors Field Service Team – new concrete pour for front apron of building prior to coating

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Tremco Vulkem’s “Extreme Wearing System” applied to the pedestrian traffic areas by Pumpcoat – fast curing and back to business!

Pumpcoat-tremco ews system

Finished Application of Tremco’s EWS system – durable waterproofing solution found by Pumpcoat

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

NRI - Neptune Research Inc

Let us solve all your pump & coating problems!

Pumpcoat

Let us solve all your pump & coating problems!

NRI - Neptune Research Inc

Let us solve all your pump & coating problems!

Pumpcoat

Let us solve all your pump & coating problems!

NRI - Neptune Research Inc

Let us solve all your pump & coating problems!

Pumpcoat

Let us solve all your pump & coating problems!

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