NOAA - Fixing A Coatings Failure

Client Needeses

Raider commercial building painters were contacted by an HVAC Fan manufacturer Toro-Aire with a big problem. They were just days away from the opening of a new (NOAA http://www.noaa.gov/ ) high-tech weather research facility in La Jolla CA that had been put on hold because a necessary exhaust fans coating had failed and the rust forming on the machine was becoming airborne and threatening other high-end machinery. With liquidated damages looming and their reputation on the line, they needed help.

This project presented several challenges and a few first-time situations for us, which we met through extensive research, solid preparation work, and constant communication with the client.

The Challenges

Some of the difficulties associated with this project included:

Location

The fan was located in an open roof mechanical room and was less than .25 miles from the ocean. The area is know for a thick marine layer through much of the summer.

Unusual Working Conditions

Large fans of this type are normally coated prior to installation. Because this was a re-coating, we had other machines that needed to be safely contained so that air intake would not be effected.

Fan Balance And Clearance

Fan blades that had tight tolerances needed to be coating while taking special care to keep them in balance. Partial Dis-assembly. During the project it was discovered that the rusting was far more extensive then assumed, and was throughout the inside of the machine. A solution is needed to include the removal of access ports and repairs to interior components.

Tight Timeline

The client had an extremely tight timeline to work within and failure was not an option.

Our Solution

Our professional crew consulted with the mortuary staff and took special precautions to address the health concerns of the environment.

The unexpected sand mortar aggregate deck beneath the existing flooring was incompatible with the specified coating application. The floor had to be resloped to meet project specifications.

We alerted the client of the old, unused pipes embedded in the concrete slab beneath the deck, which had to be removed by the mortuary.

We shot-blasted the floor with a Blastrac machine, which vacuums dust to prevent it from entering the business environment. We also used plastic sheeting as a secondary preventative measure against dust and contamination.

Our crew built curbs, poured the new floor, and added new drains. Gaps were filled with epoxy, and reblasting was performed to permit additional adhesion for the sealant.

Several coats of specialized polymer epoxy, sand, and glaze were applied to seal and finish the floor.

Our crew researched and located a formaldehyde-resistant coating and applied it to the floor.

Project Outcome (completed 2011)

The project was completed ahead of schedule, including the added scope. The client, contractor, and end user were all appreciative that we were able to hold them to their schedule. The specialty DTM product used created a great finish and with a a total of 3 coats the longevity of the finish will allow for years of operation.