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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50 MARCH 2015 COATINGSPROMAG.COM Go West, Young Man! Faltus might have had in mind Horace Greeley's advice, "Go west, young man," when he staged this project. Since the CUI spray squad works best walking backward (it keeps hoses out of the goo), and a perfect staging area existed just west of the land bridge, his crew would start in the east and work their way west. "We began by bringing in our 20-foot [6 m] enclosed trailer with spray rigs inside," Faltus said. "We trucked in a 20-foot [6 m] heated storage container to hold the paint drums and other material. We also towed in our 120 kW Generac generator and 185 CFM [5 m³/min.] Sullair air compressor." Te crew checked the concrete slab using a calcium chloride test kit, plastic sheet test, and Elcometer moisture tester. A ll systems go, they fred up their Blastrac 10-inch (25cm) propane-powered, ride-on centrifugal shotblaster loaded with 280-grit steel shot to achieve International Concrete Repair Institute (ICRI) Concrete Surface Profle (CSP) 2–3. Seven-inch (18 cm) Metabo angle grinders handled edge work and other areas that the shotblaster couldn't reach. Te CUI crew then ran magnets over the slab to pick up excess shot and blew down the surface with gas blowers. Te crew quickly set up to roller-apply a 5-mil (127 micron) (approximate DFT in a single pass) coat of Creative Polymers' UREPRIME 1305 primer, a two-component polyurethane designed to adhere to fast-setting polyurethanes and polyureas. "We had one guy at the mixing station, one runner, and three guys rolling," Faltus said. "We used nine-inch [23 cm] rollers with ½-inch [1 cm] nap covers. Te primer applied easily and worked into the concrete very well. W hile two guys rolled the primer, a third guy with spiked shoes followed behind them about 15 to 20 minutes later with an 18-inch [46 cm] roller with ½-inch [1 cm] nap cover to lay down bubbles caused by outgas- sing. I initially wanted to fat squeegee and backroll the primer, but the Creative Polymers reps didn't want me to. I thought the application would have gone faster, but they thought we might leave a little too much material in places, which could afect the cure." Monolithic Barrier After letting the primer set up for 24 hours, Faltus huddled with his crew to express the importance of getting the 100-mil (2,540 microns) (approximate DFT) Creative Polymers GEO-TEK 4950 monolithic polyurea barrier sprayed down ahead of the primer's 48-hour recoat window. Te fun was over! From here on out, they'd work anywhere from eight to sixteen hours a day, with days of staggered to keep everyone as fresh as possi- ble. To add to the pressure, this was no handpicked crew; they had been selected from CUI's pool of 150 to 200 men, based on availability. Hey, most foremen prefer to work with their own teams, but sometimes it's simply not in the cards. Tis partic- ular polyurea crew comprised two men who Faltus had worked with before, fve he had not, and a rookie. Still, Faltus had faith. "Tere was a lot of teaching going on, especially with a rookie on board," said Faltus. "Tis was a hard job, and we needed our rookie, Shane Petty, to come through. We were relying on him to pull lines, help out, act as a runner, learn, and watch. W hen a rookie doesn't perform well, things can go south real quick. You can lose time, money, and valuable spray Monumental Land Bridge The CUI crew rolled the primer on at 5 mils (127 microns) approximate dry film thickness (DFT). It had a 48-hour recoat window, so they had to get the next layer on quickly! The crew used proper safety gear wherever necessary, including boots, hard hats, Tyvek suits, chemical-resistant gloves, and 3M full-face respirators, and a 20-foot (6 m) enclosed trailer on-site trailer carrying drums and rigs for mobilization. "[The project's] huge for the city," said company vice president Steven R. Philipp, Jr. "And we feel an immense sense of corporate pride in helping connect the arch and waterfront to the downtown business district."

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