CoatingsPro Magazine

JAN 2009

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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JOB AT A GLANCE PROJECT: Install durable epoxy floor system in two hotel dining halls at popular tourist resort COATINGS CONTRACTOR: PremUS of Orlando, Inc. 16403 Myers Court Clermont, FL 34711 (407) 654-3099 www.premus.com SIZE OF CONTRACTOR: Two teams of 8 to 10 people worked on each floor PRIME CLIENT: A popular Florida theme park resort SUBSTRATE: Dry pack mudbed/thick set 12" floor tile SUBSTRATE CONDITION: Worn, could not be removed because of elevation concerns and fact that removal would create difficult-to-control dust ABOVE Since they could tap into the resort's power, the crews ran 250-ft. power cords from the ceiling into each work space to handle three- phase power. "We then hooked up transformer boxes and ran our power tools," says Rader. Not only did this eliminate fumes from gas-powered generators — it meant that the crews saved time as well. SIZE: Two floors, each approximately 6,500 sq. ft. DURATION: Project completed in 40 days UNUSUAL FACTORS: Both resorts remained open during renovation, which meant that the crews much dust and dirt, as well as change the floor's elevation. This meant that whatever coating system was specified would have to be heavy enough to be floated on top of the existing tiles. Third, since both sites were to remain open to the public, there could be absolutely no dust and no odor. In particular, any prep work would have to be done on the third shift, late at night, to avoid the public. Finally, the coatings had to meet with USDA and FDA standards since they were going to be installed in dining facilities." Rader worked with the owners' engineering staff to create a set of project specifications. He was then invited to bid on the project. "Just because we have a good working relationship didn't mean we were guaranteed the project. In fact, we turned in the highest bid," Rader says with a soft chuckle. "But we were the only ones to produce a four by eight mock-up of the job and that, combined with our obvious comfort level, helped." Rader and his crew were awarded the project — along with its tight time frame. Budgetary concerns necessitated that the floors be finished by the end of the resort's fiscal year — a date that was looming. "By the time the project was awarded we had a 32 day window to complete both floors, which was eventually extended to 40 days because of all the up-front delays. In all, we went through about six to eight weeks of design, sample changes, and mock-ups with the owner's engineers — most of it before we could start work on the floors." Rader explains that the resort's owners and engineering staff were very involved at every step. For example, the floors are located in the dining halls of two of the resorts busiest hotels. And although the work was scheduled to take place in September — at the tail end of the busy season — the areas would still be full of relaxing tourists enjoying their meals. This meant that there could be no odors allowed at all, not from Crew had to prepare and install the epoxy system over the existing tile substrate Intense 6-8 week long design, mockups, and sample stage with owner's had to install flooring with guests on the other side of thin barricades — without impacting the guests' comfort No dust and no odor were allowed in resort, even had to do a "smell test" on products before they could be specified engineers, which cut the project schedule down to 40 days and required the crews to work 7-day weeks to meet deadline Crew had to prepare existing substrate on third shift because of noise from prep equipment The 3-phase power to equipment ran in the middle of the dining area behind the movable barricades MATERIALS/PROCESS: Working in approximately 1,300 sq. ft. sections, behind contractor-built and Install 6" cove bases around floor edges using Dur-A-Flex epoxy Cove-Rez; hand-trowel to 1/8" thickness Install Dur-A-Flex modified base coat blend epoxy to fill diamond grinding and grout joints installed hard barricades, first use 30" SASE 780 dustless grinders and 7" Metabo dustless grinders to diamond grind the glaze from the tile substrate Lay out designs and stripes with chalk lines and measuring tapes according to specifications Flooring system was highly modified by resort's engineering staff with input from coatings manufacturer and coatings contractor Pour Dur-A-Chip polymer/epoxy resin floor system squeegee and backroll at Install artists' renderings of 8' tall musical notes and 7' diameter sports balls Roller-apply 3 mil WFT clear top coat of Armor Top aliphatic urethane with Dur- icons with airbrushes and mini spray guns; seal with roller-applied 10-mil thick seal coat of Dur-A-Glaze Clear A-Grip anti-slip aggregate mixed into the system to seal and protect and meet specified slip coefficient on both floors Keep total system thickness at nominal 3/16" SAFETY CONSIDERATIONS: Working while resort open to public required extra precautions Extra dust and odor remediation procedures were necessary during the product specification process Necessary safety apparel, including gloves, knee pads, dust masks, eye and hearing protection, were required on site January 2009 J www.coatingspromag.com 35 approx.120 mils thick in a specified color. Then, hand-broadcast multi-col- ored corresponding Dur-A-Chip flakes into wet resin at approx. 9 sq. ft./lb.; allow to cure overnight before applying the first epoxy seal coat Using floor buffer sanding attachments, prepare the sealed Dur-A-Chip floor topping, then vacuum

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