CoatingsPro Magazine

SEP 2016

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COATINGSPRO SEPTEMBER 2016 39 so fall protection was not necessary while crew members were on the lifts; however, extreme caution was exercised at all times. e six-man crew used Metabo 7-inch (17.8 cm), handheld diamond grinders to prepare the surface and remove all mastic and adhesive on the 5,620 square feet (522.1 m²) of wall area. e surface preparation was very labor intensive, as the crew was holding the 15- to 17-pound (6.8–7.7 kg) grinders against a vertical surface. "e surface prep took a significant amount of time. We needed to make sure to remove all remnants of the adhesive and create a uniform surface for the application of the pretreatment material," stated Puszynski. T he pretreatment material used was PIP 's Protect A M-PT-BW, a single-component antimicrobial penetrant that is designed to create a moisture barrier. T he material forms a colloidal gel that is antifungal and antimicrobial and penetrates 2 to 4 inches (5.1–10.2 cm) into the substrate. According to the PIP technical data sheet, Protect A M-PT-BW penetrates the concrete substrate and reacts w ith free alkali and/or alkaline hydrates, internally producing an extremely dense silica hydro-gel w ith antimicrobial and antifungal properties that fill the micro spaces and voids around ag gre- gate or in block. T his hydro-gel permanently seals the matri x blocking water, vapor, or contaminant movement at 50 –100 square-foot per gallon (1.2–2.5 m² per liter). "We spray applied the Protect AM-PT-BW using a high-vol- ume, low-pressure sprayer. is layer is extremely important because if there should ever be a breach of the coating system, the wall surface will still have antimicrobial properties," explained Puszynski. e Protect AM-PT-BW is specially formu- lated for walls, as it is more viscous than its floor counterpart. After waiting 24 hours and allowing the material to fully penetrate into the concrete walls, the crew was ready to apply the Protect 1200 AM-WR primer. is antimicrobial two-compo- nent, water-reducible epoxy primer was applied with rollers at a thickness of 5–6 mils (127.0–152.4 microns). "After the primer had cured — about two hours — it was time for the application of Protect 1000 AM, an epoxy resin filler. is material was flat troweled on in two coats. It is used like spackle to fill irregular- ities and level out the substrate," said Puszynski, who added that, although the thickness will vary, it averaged 30 mils (762.0 microns) per layer. is epoxy resin was applied over the course of two days, and according to Puszynski, the goal was to create walls that were like a sheet of glass: easy to clean and sanitize and free from imperfections that can catch dirt or other contaminants. At this point, the crew stopped work on the walls and moved to the 1,715-square-foot (159.3 m²) floor area of the giraffe exhibit. A rounded cove base was created along the bottom of the wall, eliminating any angles or transition areas where dirt or other materials could be captured. "We wanted to complete the floors before the final wall coating was applied so that the entire enclosure was seamless. We covered the floors once the finish coat had cured, and we went back to roller apply the finish coat — Protect 2000 AM — at a thickness of 4–5 mils [101.6–127.0 microns] to the walls," stated Puszynski. JOB AT A GLANCE PROJECT: Apply an antimicrobial coating system to the floor and walls of the indoor area of the giraffe exhibit at the Niabi Zoo COATINGS CONTRACTOR: Concare Inc. 2081 N 15th Ave. Melrose Park, IL 60160 (708) 681-8800 www.concare.com SIZE OF CONTRACTOR: ~43 employees SIZE OF CREW: 6 crew members PRIME CLIENT: Niabi Zoo 13010 Niabi Zoo Rd. Coal Valley, IL 61240 (309) 799-5107 www.niabizoo.com SUBSTRATE: Concrete and concrete block CONDITION OF SUBSTRATE: Good SIZE OF JOB: 1,715 sq. ft. (159.3 m²) on the floor, 5,620 sq. ft. (522.1 m²) on the walls DURATION: 8 days UNUSUAL FACTORS/CHALLENGES: » The enclosure needed to have an antimicrobial and seamless system. » Hoof Guard 36 was broadcast into one of the coating layers to act as a natural nail file for the hooves of the giraffes. MATERIALS/PROCESSES: To the walls: » Removed the existing fiberglass panels (FRP) with Metabo grinders » Spray applied Protect AM-PT-BW, an antimicrobial penetrant, at 50–100 sq. ft. per gallon (1.2–2.5 m²/L) » Roller applied Protect 1200 AM-WR primer at 5–6 mils (127.0–152.4 microns) » Trowel applied Protect 1000 AM in two coats at an average thickness of 30 mils (762.0 microns) » Roller applied Protect 2000 AM at 4–5 mils (101.6–127.0 microns) To the floors: » Removed the existing rubber mats and mastic with Airtec scarifiers » Spray applied Protect AM-PT per specs at 150–200 sq. ft. per gallon (3.7–4.9 m²/L) » Trowel applied Protect AM-UC-RP and broadcast Hoof Guard 36 to rejec- tion at approximately 5 ⁄16 inch (7.9 mm) » Roller applied Protect 2000 AM-UR at 15–16 mils (381.0–406.4 microns) SAFETY CONSIDERATIONS: » Wore dust masks, safety shoes, safety glasses, and Tyvek protective suits, when necessary

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