Secondary Containment Coating NJ

Project Overview: Secondary Containment Coating Installation for Chemical  Manufacturer 

Existing Conditions: Our client at this chemical facility manufacture aluminum chloride and asked us to create a chemical resistant containment system for their existing reactor area and tank farms. These areas had previously been coated with an inferior product and were showing signs of chemical attack and environmental abuse. The existing coating was over ten years old and had delaminated to expose the concrete substrate. A delaminated coating is bad in any scenario but due to the corrosive nature of the chemicals in the tank farm, it was imperative this installation be performed as quickly as possible to prevent further harm to the subfloor.

Preparation of existing conditions: A full remove of the existing coating was the first step in the preparation phase in order to establish a sound substrate. Once the coating was fully removed

we had to pressure wash the area to remove contaminants and neutralize the concrete. Once the power washing was completed we prepared the entire surface using hand grinders as the area was too confined for our typical diamond grinders, we also had to prepare the vertical walls in order to prepare the walls to be coated.  Once the mechanical profile was established on both the floor and walls we vacuumed both areas to ensure the coating would bong to the substrate. Before we could begin coating, our final step was to repair any spalted or delaminated surfaces using engineered concrete.

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Installation: we began by applying a brand new product from GP called steel seam to all joints and structural cracks. STEEL-SEAM FT910 is a 100% solids epoxy surfacing compound for steel or patching compound for concrete. It was perfect for this installation as it was outdoors and this product can tolerate temperatures as low as 35 degrees and exposure to moisture during the curing process. This product is also specifically made to fill bug holes, tie rod holes, cavities, honeycombs and other surface defects on horizontal, vertical, or overhead surfaces and to form transition coves at vertical and horizontal coves steel uses. Once the steal seam was applied we installed our cove base using a mortar system and all wall to floor joints creating a 45-degree angle. Once the cove was applied we installed a wear coat of Fastop 12s 3/16 urethane cement. Once the wear surface was down we broadcast to rejection using 40/60 mesh silica sand. Once the fastop was cured enough to allow foot traffic we swept off the excess sand and stoned the floor to remove and imperfections to create a consistent finish. Finally, we installed the topcoat of Fastop TC urethane cement coating to all surfaces.

Conclusion: With the weather rapidly cooling and this being an outdoor installation we needed to act fast to make sure this installation was completed before things could take a turn for the worse. Working hand in hand with our client we were able to order the material and mobilize our crew in less than three days.