New Technology and Training Center Needs Coatings
When Precision Machine Tool Solutions contacted us in August 2012 for a commercial floor coating, we didn't appreciate the full scope of what they were going to create in their new facility. At the time, it had just seemed like another retrofit of an existing building. But the owner, Randy Heck, had much more in mind. He was creating a state of the art facility to demonstrate and train around their various lines of CNC machining equipment.
Based in Sinking Springs, near Reading, this Pennsylvania company was expanding an existing building and relocating their offices. They had found STRONGHOLD FLOORS via a reference from a Lancaster-based shared customer, Medical Devices LLC (we had completed three different projects for them).
Our coatings projects for Medical Devices LLC had entailed the installation of nearly 10,000 square feet of multiple layers of epoxy to create a durable, clean, and easy to maintain floor in their production floor. While this floor was just 4,000 square feet, Precision Machine Tool Solutions needed more.
Coatings Requirements
Precision Machine Tool Solutions needed a floor that met the following requirements:
- Easy to clean and maintain.
- Provided very high scratch resistance.
- Durable enough to withstand forklift traffic and CNC machining equipment that could present over 5,000 pounds per square inch of compressive force onto the coatings.
- Provided good color stability under the florescent lighting.
- Showcased their equipment.
Existing Concrete Surface Conditions
Given these requirements, STRONGHOLD FLOORS had to overcome some issues present in the existing bare concrete floor. This floor presented the following challenges:
- Floor was cut, jointed, or cracked into approximately 10 different slabs.
- Floor had metal posts and cut off bolts projecting out of the concrete slab.
- Slab had surface spalling and minor damage from years of use as a truck maintenance facility.
- Concrete floor was not sealed and had some minor contamination from engine oil and other petroleum based products.
- Floor joints were not level in several locations.
- Moving heavy loads into the main floor area was going to cause vibration between the slabs.
Installing the Coatings Solution
We presented PMTS with a proposal that could meet all of the requirements and alleviate (or minimize) the problems with the existing concrete floor. The customized floor coating solution involved a four layer polymer floor coating where the total thickness was approximately 3/32". Reinforced with sand in two of the layers, this epoxy coating system is extremely durable and can withstand heavy loads. PMTS accepted and we got to work.
The primary work was completed in just four days. That allowed the construction process to quickly resume and get them ready for their opening. Below, we detail all the steps we took for the entire installation.
Several days before beginning the main floor preparation and coatings, one of our crews chased out all cracks and saw cuts with our shrouded crack chasers. Once cleaned out and vacuumed, they added backer rod into the cuts and then filled them with epoxy joint/crack fillers chosen for their rigidity and ability to withstand some movement. These materials were overfilled to allow subsequent grinding to make flush with the main floor surface. All metal posts were cut off or pounded into the slab and the open holes and spalls were also filled.
To allow PMTS staff to still come and go, all main floor activities were timed to allow the PMTS staff to walk protected areas of the floor each day. The breakdown of coatings is as follows:
On Wednesday of the following week, we prepared the entire surface with our diamond grinders. As three phase power was present, we were able to utilize our largest class of surface grinders which weigh in excess of 1,100 lbs. This allowed us to rapidly prepare the over 4,000 square feet and get a deep scratch pattern for an excellent bonding profile. After additional surface repairs, the entire surface was cleaned. Then, after PMTS staff had left, the entire concrete floor was coated with a thick layer of epoxy and hand broadcast with sand until the surface was saturated.
On Thursday afternoon, the excess sand was removed and the entire surface was once again coated in a pigmented epoxy and broadcast with sand until refusal.
On Friday afternoon, the excess sand was removed and a pigmented layer of 100% solids epoxy was applied in a very heavy layer, where most of the profile from the sand was overcome.
On Saturday, with no PMTS staff present, we applied a pigmented, aliphatic urethane with a tabular aluminum additive that creates a very scratch resistant final coating.
Several weeks later, the remaining open joints were filled with a gray caulk to allow the coated floor to move where the heaviest loads transitioned across pads, but still act as a seamless surface.
The Grand Opening
On May 1st 2013, Randy and his staff celebrated the culmination of their efforts with the grand opening of their new Technology and Training Center. We received an invitation and gladly accepted.
When we arrived, we had no idea the scope of this event. Several hundred people attended and PMTS put on a fantastic event. Everyone was treated to great food and drink and allowed to freely browse the new facility. Many product vendors were there to assist with demonstrating the full potential of the extensive product lines on the facility's main floor.
It was great to see the once empty main floor now filled with so many people, heavy machines, and demonstration tables.
While there, we were informed that several PMTS customers wanted to chat with us to see how we might assist them too. I also found out that a PMTS customer in Milton, PA is a company owned by people with whom I attended high school. All around, it was a great day and a great event.
While I cannot begin to understand what all of their equipment is used for, I have to believe that if your company uses CNC equipment, Precision Machine Tool Solutions is the place to call.
