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The Energy Innovation Center’s approximately 80-year-old concrete floor had significant divots and was badly spalled and cracked. The concrete floor, often referred to as “The Racetrack” due to its oval shape, serves as the main hallway to a newly renovated technology hub and needed significant structural and aesthetic work. The re-finished floor had to offer durable functionality as well as blend into the neo-industrial look of the re-tasked building.
The Energy Innovation Center’s approximately 80-year-old concrete floor had significant divots and was badly spalled and cracked. The concrete floor, often referred to as “The Racetrack” due to its oval shape, serves as the main hallway to a newly renovated technology hub and needed significant structural and aesthetic work. The re-finished floor had to offer durable functionality as well as blend into the neo-industrial look of the re-tasked building. This paper will cover the building’s history; the key challenges of repairing an aged concrete floor; surface preparation and cementitious overlay requirements prior to the installation of a high-performance floor coating; the science behind contemporary waterborne polyurethane coatings used in the flooring market. Readers will also gain an understanding of the application techniques, challenges and final results of a waterborne polyurethane coating used in a largescale commercial application.
Styrenated Unsaturated Polyester & Vinyl Ester coatings are accepted for use in chemical immersion tank linings. The primary advantage is the increased chemical resistance to harsh commodities and fast turnaround time compared to epoxy coatings. However, styrene is becoming heavily regulated due to its safety and health concerns.
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Failure of flooring materials is usually due to a combination of factors rather than a single, simple cause that led to below expectation performance. For example, construction on a less than high quality concrete slab on grade, combined with the absence of a vapor retarder, with residual concrete wear and contamination, followed by inadequate surface preparation, and finally poor coating selection applied during inclement ambient conditions that is turned over early to severe service is a recipe for disaster.
Corrosion under Insulation (CUI) is accelerated corrosion that takes place under insulation typically used to conserve energy, help with process control, and protect workers from temperature extremes. CUI is an issue for facility owners in many industries that use heat or cold in their industrial processes, including chemical processing, refining, fertilizer manufacturing, and power generation. Insulation used in these applications is generally mechanically attached to the substrate vessel or pipeline and is typically covered with cladding. Cladding is typically made out of metal or plastic and is applied to protect the insulation from physical damage and to keep water away from the insulation and substrate.