CoatingsPro Magazine

MAR 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 MARCH 2015 49 Philipp turned to Creative Polymers president Rodney Jarboe, who drew upon more than three decades of experi- ence as a polymer coatings chemist. He suggested topping the 100-mil (2,540 microns) polyurea system with a slower curing 50-mil (1,270 microns) polyurethane system into which the crew could embed a layer of 8-ounce (227 g) geotextile fabric. "You have to have at least fve to ten minutes of open time to install the fabric," said Jarboe. "Polyurea cures in seconds, and you really can't slow it down to more than a minute or two, so we went to slower-curing polyurethane to bond the geotex- tile into." Tinking the additional polyurethane/fabric layer would act as insurance against a potential disaster of titanic propor- tions, the specs changed to 150 mils (3,810 microns) total dry flm thickness (DFT) of primer, polyurea, polyurethane, and geotextile fabric. Te spec rewrite delay had Faltus and his eight-man crew chomping at the bit, but the time had fnally come to get this two-week project started! U.S. Navy's deep submergence vehicle preserved for Undersea Museum in Washington State Q.E.D. Systems, Inc. 1305 Lumsden Rd. Port Orchard, WA 98367 (360) 373-9551 www.Qedsysinc.com with: Propulsion Controls Engineering 920 W. Marine View Drive Everett, WA 98201 (425) 257-9065 www.pceshiprepair.com SIZE OF CONTRACTOR: A five-man crew worked this project PRIME CLIENT: Naval Undersea Museum 1 Garnett Way Keyport, WA 98345 (360) 396-4148 SUBSTRATE: Metal SUBSTRATE CONDITION: Rusting, deteriorating with corrosion cells SIZE: 4,500"² (29,032.2cm²) originally, 24,000"² (154,838.4cm²) final DURATION: Approximately 2 months UNUSUAL FACTORS: » Needed to renegotiate a part of the contract for more repairs » Discovered massive running rust, deteriorated metal, corrosion cells, small trees, and duct tape on the vessel MATERIALS/PROCESS: » Inspected surface and interior of Submersible for deterioration » Followed SSPC-SP1, Solvent Cleaning; SSPC-SP2, Hand Tool Cleaning; and SSPC-SP3, Power Tool Cleaning protocol » Applied Ship-2-Shore Industrial on rusted areas » Spray-applied epoxy coating (MIL-PRF-23236) in two coats to achieve 12 mils DFT (0.305mm) » Spray-applied topcoat (MIL-PRF-24635), Steel-Master 9500 silicone alkyd to achieve 4 to 6 mils DFT (0.102mm to 0.152mm) » SAFETY CONSIDERATIONS: » Coating contractors wore North full-faced respirators, Miller Maynard II fall protection, and Tyvek suits » Scaffold contractors wore Miller harnesses 100% of the time JOB AT A GLANCE PROJECT: COATINGS CONTRACTOR: COATINGS CONTRACTOR: JOB AT A GLANCE PROJECT: Install a 150-mil-thick (3,810 microns) waterproofing system atop a newly built concrete land bridge near the St. Louis Arch Coatings Unlimited, Inc. 4325 Bridgeton Industrial Dr. St. Louis, MO 63044 (800) 628-4145 www.coatingsunltd.com SIZE OF CONTRACTOR: About 150–200 full-time employees SIZE OF CREW: 8 crew members PRIME CLIENT: National Park Service Jefferson National Expansion Memorial 11 North 4th St. St. Louis, MO 63102 (314) 655-1700 www.nps.gov SUBSTRATE: Concrete CONDITION OF SUBSTRATE: New SIZE OF JOB: About 25,000 sq. ft. (2,323 m²) DURATION: 2 weeks UNUSUAL FACTORS/CHALLENGES: » Tons of topsoil placed over waterproofing system to support trees, bushes, plants, lawns, and benches » Fast-cure polyurea was followed almost immediately (30 to 45 minutes) by slower-cure polyurethane to allow installation of geotextile fabric and to prevent earthmoving equipment from damaging primary polyurea coating MATERIALS/PROCESSES: » Checked substrate using plastic sheet test, moisture meter, and sodium chloride test kit » Prepped concrete surface with centrifugal shot blaster to International Concrete Repair Institute (ICRI) Concrete Surface Profile (CSP) 2–3 specifications » Used magnets to pick up spent steel shot and blowers to clean substrate » Rolled in one pass 5 mils (127 microns) approximate dry film thickness (DFT) Creative Polymers UREPRIME 1305 primer » Spray-applied in one pass 100 mils (2,540 microns) (approximate DFT) of fast-setting Creative Polymers GEO-TEK 4950 » Spray-applied in one pass 50 mils (1,270 microns) (approximate DFT) of slow-setting polyurethane, Creative Polymers PLIA-THANE 4975 » Rolled and embedded a layer of US Fabrics' 8-ounce (227 g) geotextile material with 6-inch (15 cm) overlaps SAFETY CONSIDERATIONS: » Wore boots, hard hats, Tyvek suits, chemical-resistant gloves, and 3M full-face respirators where warranted The crew got right to surface prep on this ~25,000-square-foot (2,323 m²) surface. They used a ride-on centrifugal shotblaster and angle grinders to achieve International Concrete Repair Institute (ICRI) Concrete Surface Profile (CSP) 2–3. An eight-person crew from Coatings Unlimited, Inc. (CUI) was brought in to waterproof the new concrete land bridge over I-44 near the Jefferson National Expansion Memorial park, and, therefore, the St. Louis Arch.

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