How do you remove 1/4 inch of tuff Epoxy/elastomeric Urethane from 350,000 square feet of parking deck on 5 different levels in a timely manner?
Case Study: Elastomeric Urethane membrane removal at the Philadelphia Parking Authority facility next to the Philadelphia Convention Center, 350,000 square feet
This was a very sensitive project in that the deck needed major restoration and concrete replacement and scheduling was very critical due to the fact that the Philadelphia Convention Center relied on this structure for most of its parking.
During the scarification process the membrane is chipped away using carbide cutters, leaving the concrete with a profile of CSP 6-9, this profile is too rough for some material manufactures so we can diamond-grind the surface to reduce the profile to the material manufacturers requirements. Next, we shot blast the surface to remove any laitance and micro fracturing caused by the scarification process. The deck is now ready for material applications.
Philadelphia parking garages see heavy traffic, so maintaining proper maintenance is necessary. The main purpose of parking deck membranes is to protect the concrete deck from water and salt intrusion, which can eat away at rebar and the supporting structure. When the deck is prepared properly and a high performance membrane system applied, it can last from 10 to 20 years.
The General contractor for this project was Melrose Construction, Inc. of North Wales, PA. When Bob DiFerdinando, Project Manager for Melrose, decided on who was going to do the surface preparation, he chose Shot Blast Inc. because of our preparation and membrane removal capabilities. No other preparation contractor had the necessary equipment and expertise to do this type of work in the time frame allotted. This project turned out to be a major success for Melrose Construction and the Philadelphia Parking Authority.
Parking garages see a lot of traffic (pun intended), so it’s important that the flooring remains in good condition. Parking decks are covered in a polymer coating that protects the surface from normal contaminants. This membrane coating needs to be removed every 10-15 years to ensure that the surface remains durable.
Pharmaceutical drug distributor Priority Solutions recently moved into a new facility. When they needed floor finishing, they called Shot Blast Inc. for help. After going over our various floor finishes, they decided that a concrete floor polish was the best choice for them. They opted out of a coating system because they preferred minimal maintenance.
The polished concrete they chose is a surface that is easy to clean and does not require dusting. Because there is no coating, the team at Priority Solutions will never have to worry about the floor chipping or peeling.
The existing floor was in bad shape from the previous tenants. It was spalled and had so many divots that it was a dangerous working environment. Our team made repairs by saw cutting around the area to create a vertical wall, and then a high strength (6,000 psi) concrete was mixed to fill in the divots. All cracks and joints were filled with a two-part polyuria polymer.
This job was focused on fixing up the commercial kitchen area and involved a number of steps. Our process was as follows:
1. Diamond grind to remove old coatings from floor area.
2. Prime with two component epoxy. Fill all holes and cracks using flexible epoxy.
3. Apply High build two-component epoxy and broadcast quartz until rejection.
4. Sand floor to even out texture.
5. Apply top coat of two component Urethane mortar for non-slip and easy
We recently completed a job at Winnie’s LeBus Restaurant on Main Street in Manayunk, Pa.
Winnie’s main kitchen had a badly cracked ceramic tile floor with a concrete sub-floor that was unstable. When the floor was cleaned, water would run through the cracks into the lower level kitchen. The ceramic tile and concrete sub-floor were completely removed down to the floor joist.
Then two layers of ¾” plywood were screwed down to the joist. We now have a stable base to install the Urethane Mortar flooring system to the plywood surface. Before application could begin, all plywood joints were taped with fiberglass mesh and a flexible epoxy water proofing membrane. After the joints cured, the flexible epoxy membrane was applied to the entire plywood surface.
Then the Tile Red Urethane mortar was troweled down at ¼” in thickness and backrolled. While still wet, Quartz was broadcast into the wet Urethane until rejection. This was allowed to cure then we came back and vacuumed all excess quartz from the surface. Then the top layer of Urethane Mortar was applied with squeegees and backrolled to level surface.
This system is designed for high volume kitchens where daily cleaning with hot water (steam) and detergent is necessary to remove all the grease from the kitchen floor. This system holds up much better then epoxy systems which crack when subjected to hot and cold temperatures.