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COATINGSPRO SEPTEMBER 2015 53 Before ink ing the dea l, Desco Co - Ow ner Mark Ver r y sized up the project. Nor ma l ly, g iv ing a 23,000 -square-foot (2,136.8 m²) concrete f loor the delu xe treatment might ta ke his crew a week or so. But the Ind iana Grand never c loses. To ma ke matters tr ick ier, the f loor plan was such that the job needed to be d iv ided into dozens of ind iv idua l areas rang ing f rom 50 square feet (4.7 m²) to 1,400 square feet (130.1 m²). T he areas wou ld need to be bar r icaded. A nd a long w ith the vacuum systems that cou ld control airbor ne dust f rom g r ind- ing , hopef u l ly Key Resin's low-volati le organic compound ( VOC), low- odor mater ia ls wou ldn't dr ive gamblers away f rom the slot machines. Considering everything, Verry asked for six weeks. Te casino gave him four. Verry politely pointed out that even the smallest areas required the same time-consuming steps as the largest. But the casino wasn't playing tough for the sake of playing tough; they needed the new fooring installed prior to their annual Kentucky Derby party! Escorted Off the Premises! Access to the casino f loor was deceptively easy. A fter background checks, the casino issued the Desco crew security badges. With that formality behind them, the crew simply backed their Ford pickup trucks to loading docks behind the casino and began hand-trucking gear and material to various staging areas inside. It took no time to find out that the security badges also gave them access to the employee's lunch To star t the process, the four-person crew star ted with preparing each area — ranging from 50 square feet (4.7 m²) to 1,400 square feet (130.1 m²) — of the concrete floor. They used grinders and filled all cracks with caulk. JOB AT A GLANCE PROJECT: Repair cracks, apply flexible membrane, and install new flooring system at a busy casino COATINGS CONTRACTOR: Desco Floor Systems 1851 E Bdwy. Fortville, IN 46040 (317) 485-0060 www.descofloors.com SIZE OF CONTRACTOR: ~42 full-time employees SIZE OF CREW: 4 crew members PRIME CLIENT: Indiana Grand Racing & Casino 4300 N Michigan Rd. Shelbyville, IN 46176 (877) 386-4463 www.indianagrand.com SUBSTRATE: 10-year-old concrete floor with acrylic cementitious flooring system CONDITION OF SUBSTRATE: Significant cracks in the concrete substrate and existing cementitious flooring system due to movement of the slab SIZE OF JOB: ~23,000 sq. ft. (2,136.8 m²) DURATION: 6 weeks UNUSUAL FACTORS/CHALLENGES: » Casino remained open during the entire project » Exact cause of concrete cracks never fully known MATERIALS/PROCESSES: » Drilled 2-inch (5.1 cm) core samples to determine condition of substrate » Ground floor to give epoxy a gripping surface » Ground larger cracks, and filled all cracks with commercially available caulk; troweled smooth » Troweled and squeegee-applied approximately 40 mils (1,016.0 microns) dry film thickness (DFT) Key Resin's 580 liquid-applied membrane in one pass » Troweled and squeegee-applied in one pass approximately 8–14 mils (203.2–355.6 microns) DFT coat of Key Resin's 511 Epoxy Binder/Glaze to build mils and establish sky-blue color » Troweled and squeegee-applied in one pass a (approximately 30 mils, or 762.0 microns DFT) coat of Key Resin's 511 Epoxy Binder/Glaze; spritz with denatured alcohol and otherwise manipulate still-wet 511 to create illusion of clouds on floor » Dipped and rolled a single 3- to 5-mil (76.2–127.0 microns) DFT pass of Key #467 Urethane Topcoat SAFETY CONSIDERATIONS: » Care required while working with casino patrons nearby » Used safety barriers to prevent patrons from walking on still-wet floors » Wore security badges at all times