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.
Issue link: http://coatingspromag.epubxp.com/i/72303
JOB AT A GLANCE PROJECT: Apply intumescent coatings to approx. 80,000 sq. ft. (7,432m2 ) of structural steel/equipment supports/tower vessel skirts for hydrocarbon refinery expansion project COATINGS CONTRACTOR: Pro Kleen Inc. dba PK Industrial PKI Kansas Facility 5351 SW 100th Street Augusta, KS 67010 (316) 775-6898 www.PKIndustrial.com PKI HOUSTON FACILITY ABOVE Once the connections had been blocked out, "intumescent fireproofing is applied by spray and hand trowel per specific application specifications," says Larry Nichols, PKI's marketing manager. with a top coat. In general, better than 90% of the intumescent fireproofing is applied in the shop locations, therefore alleviating the need for complicated manpower and scaffolding needs, contractor congestion, and downtime within a working facility. " But what would be applied? There are a number of passive fire protection materials on the market that meet UL 1709 standards for hydrocarbon pool fires, including hi-density concrete, light- weight cementitious products, and epoxy-based materials. Each has advantages and disadvantages, including cost, shipping durability, weight, various curing wait times to be able to ship coated steel without damage, as well as the fact that different products require different on-site finishing steps. "The owners chose to go with an epoxy intumescent for this project for a few reasons. One was the fact that epoxy intumescents have the smallest block-out areas, which allows the most work to be done offsite, making this a safer project. The second reason is the shipping durability of epoxy intumescents. They simply require less touch-up due to shipping damage than other materi- als," explains Turpin. LOGISTICS, LOGISTICS "The job included three project locations: Shop application of 'stick steel' at PKI's office in Augusta, Kansas, followed by block- out finishing in Decatur, Alabama, once the steel beams were assembled into modules. The third and final step would be the full assemblage of the pipe bridge truss modules, each a 9' (2.74m) wide by 70'- to 90'-long (21.34m to 27.43m) section, all applied with epoxy intumenscents. That third step took place on site in Bushton, Kansas," Turpin explains. "The project was divided between modular steel and support steel, which were provided by the same supplier but had to be delivered to different locations from PKI's shop, creating a need for intensive logistical management," Turpin continues. "Turner Industries was the general contractor (GC) with Burns & McDonnell 4800 Fidelity Street Jacinto City, TX 77029 (855) 759-2800 SIZE OF CONTRACTOR: 50 shop workers/15-20 modular shop workers/20 onsite workers PRIME CLIENT: Burns & McDonnell was main client (Engineer); Turner Industries was the general contractor SUBSTRATE: Structural steel all black (mill scale) SUBSTRATE CONDITION: New SIZE: 80,000 sq. ft. (7,432 m2 DURATION: 8 months broken into two 4-month spans UNUSUAL FACTORS: ¢ Project encompassed 3 different job sites for one project ¢ Project was divided between modular steel and support steel, which were provided by the same supplier but had to be delivered to dif- ferent locations from PKI's shop, creating a need for intense logistical management ¢ Steel within the same modules contained some pieces that were desig- nated 2-hour and some that were designated 3-hour, which entailed a highly detailed tracking system while they went through PKI's shop ¢ Pipe Bridge Modules came to PKI in "truss" form. Welded members were 9' (2.74m) wide and 70' to 90' (21.33m to 27.43m) long. PKI logistical team was responsible for the freight of these trusses with an end destination of Decatur, AL ¢ Shop applications (Augusta, KS) and mod shop block-outs (Decatur, AL) were performed at the same time, which created a massive scheduling effort to ensure enough steel was provided from PKI's shop to not create delays on the modular fab shop. Same PKI management team was responsible for both projects in KS and AL at the same time ¢ Mod shop block-outs were done during winter in Decatur, AL, and it actually snowed! Night and morning temps below acceptable levels, ) July 2012 J www.coatingspromag.com 71