CoatingsPro Magazine

JUL 2015

CoatingsPro offers an in-depth look at coatings based on case studies, successful business operation, new products, industry news, and the safe and profitable use of coatings and equipment.

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COATINGSPRO JULY 2015 37 JOB AT A GLANCE PROJECT: Install modified fluoropolymer roof coating system on the Mercedes-Benz Superdome COATINGS CONTRACTOR: Brazos Urethane 1031 6th St. N Texas City, TX 77590 (866) 527-2967 www.brazosurethane.com SIZE OF CONTRACTOR: ~140 employees SIZE OF CREW: 14 crew members PRIME CLIENT: Mercedes-Benz Superdome 1500 Sugar Bowl Dr. New Orleans, LA 70112 (504) 587-3663 www.mbsuperdome.com SUBSTRATE: Spray polyurethane foam (SPF) covered with polyurethane coating system CONDITION OF SUBSTRATE: The 10-year-old foam and coating system were in very good condition, although the topmost portion of dome had birdbaths and bubbles SIZE OF JOB: About 450,000 sq. ft. (41,806.4 m²) DURATION: ~75 days UNUSUAL FACTORS/CHALLENGES: » Existing acrylic topcoat still had plenty of life left; coating project done to keep roof under warranty, brighten look, and get away from routine pressure washing » National Football League games and other Superdome events kept crew off of roof at times » Crew staged coatings pumps inside a huge rain gutter that ran along the perimeter of the dome MATERIALS/PROCESSES: » Pressure-washed roof with Quest United Cleaning Concentrate (UCC) and rinsed » Filled low spots with Quest Roof Mate Butter Grade Sealant » Cut out high spots and bubbles; filled with BASF closed-cell, high-den- sity foam » Spray-applied 8–9 mils (203.2–228.6 microns) dry film thickness (DFT) of Quest Kymax acrylic waterproofing basecoat in one pass » Spray-applied in two passes a total of approximately 4 mils (101.6 microns) DFT Kymax Kynar-modified fluoropolymer topcoat SAFETY CONSIDERATIONS: » Wore fall protection and purchased brand new fall protection for this project » Left the dome whenever lightning storms cropped up » Wore respirators when spraying working platform inside the rain gutter." Te Brazos team intended to mix coatings inside the warehouse, use International Pump Manufacturing pumps to transfer the coatings into drums on the working platform, and remix the material again to guard against settling. Tey'd then use Graco GH 833 gas-powered pumps to deliver the coatings to Graco Silver Plus spray guns through a maximum of 750 feet (228.6 m) of Exitfex hoses. It was a good plan, but a Mount Everest-sized problem cropped up! Like Sherpa, the crew needed to haul supplies from base camp to their high altitude warehouse. Despite having motor- ized pallet jacks and a freight elevator at their disposal, the round trip was taking too long! "We knew going in that the logistics weren't going to be normal," said Keller. "But we encountered a huge bottleneck at the freight elevator. Te Superdome is a very busy place — even between events — and there were too many other trades competing for the lift." Keller surmounted this problem by commandeering another elevator — and making sure his crew had the only key for it! Unafraid of Rope Work Like a trail-hardened mountain guide, Keller knew exactly what type of men he needed for this high-fying project. Te work was grueling, the pace fast, and the surface slick and steep, especially near the lower edge of the dome. Keller needed men unafraid of rope work but extremely safety sav v y. "Tere were no green peas," Keller said of his handpicked crew. "Most guys had been on the dome several times before, and all others were experienced with roofng, spraying, and working on ropes. It's important that the guys are comfortable working at heights." Crew access was through two 30- by 42-inch (76.2 cm x 106.7 cm) hatches at the top of the dome. To provide secure anchor points for their 400-foot-long (121.9 m) Webb-Rite Safety ropes, the men fastened ½-inch (1.3 cm) steel cables to Although the roof had some birdbaths and bubbles, it was in very good condition. The reason for the new coatings was to keep the roof under warranty, brighten the look, and avoid routine pressure washing.

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