It isn't enough for maintenance professionals today to simply keep up their facilities. In addition to meeting the demands new loads and change of use places on a facility, industrial building owners and educational institutions are pressured to utilize environmentally-friendly solutions that still offer extreme durability.
Case in point is a printing facility operated by one of the nation's largest newspapers that was experiencing problems with their slab-on-pile warehouse. The warehouse depends on the assistance of Automated Guided Vehicles (AGV) to carry rolls of paper that weigh in excess of 4,000 pounds. The floor began to experience extreme reflective cracking due to the large loads. This cracking affects the performance of the AGVs and needed to be repaired to ensure the facility was operating at maximum efficiency. Additionally, heavy loads, repetitive pathing and sharp turn angles of the AGVs were causing extreme wear to the concrete as the wheels of the AGVs ground into the surface.
Stop the Presses
To address these concerns, the company hired Structural Preservation Systems (SPS) - a Baltimore-based specialty-contracting firm, to perform the repairs. Initial inspections of the facility by SPS revealed that there was a construction defect - the rebar was placed too low in the slab to handle the large loads - and this deflect led to the reflecting cracks. Although another company was working on conventional repairs in a different area of the warehouse, they were over budget and had surpassed the estimated time of shutdown and repair. Recognizing that time was of the essence and the frustration level was high. SPS suggested an innovative repair strategy involving Tstrata TR (Tensile Reinforced Flooring System), which is a polymer resin flooring system that incorporates Hardwire® High Strength Steel Reinforcement and a high-wear UV stable, clearcoat finish.
An engineered solution, the Tstrata floor strengthening systems enhance the tensile strength of concrete surfaces without increasing thickness more than one-fourth of an inch. Featuring Hardwire® Steel Reinforcement and advanced polymers, the Tstrata systems strengthen the existing floor and allow for instantaneous curing with UV light technology. The system minimizes operational disruption associated with conventional concrete repairs. Providing a reinforcing repair and a beautiful finish that is chemical resistant, seamless, slip resistant and easy to clean, the tensile reinforcement and optional static dissipative features of Tstrata are optimal for industrial warehousing and manufacturing facilities that utilize fork trucks and Automated Guided Vehicle (AGV) material handling equipment.
For this printing facility, the incorporation of Hardwire® allowed the floor to have adequate tensile strength and support. The AGV systems employed by the printing facility required a static dissipative flooring system which was easily incorporated into the durable Tstrata TR flooring system. Like all Tstrata Flooring Systems, the unique UV curing finishing system allowed the floors to be immediately put back in service following installation. And, by utilizing the Tstrata TR system, SPS was able to employ a progressive repair approach that required shutdown of the facility in sections for only a couple of days over weekend periods. Other methods would have required a lengthy shutdown and would have required removing the existing floor and rebar and replacing it. SPS was able to save the newspaper both time and money with this approach.
Back to School
Today's educational facilities also are growing increasingly concerned about the effects that repair and retrofit materials have on their structures, as well as their staff and students. Parents have learned more about the effects that chemicals can have on their children so they have taken an active interest in the materials being used on projects at schools and want to ensure that no Hazardous Air Pollutants (HAP) or Volatile Organic Compounds (VOC) are used.
Case in point is the Winneconne Community School in Winneconne, Wis. The structure was experiencing several unattractive cracks that were concerning to parents and school officials in an 11-foot by 65-foot passageway that connects the middle school to the high school. Originally constructed in 1998 as a concrete slab-on-grade floor with enclosed heating elements, the corridor has five sets of double doors with three that serve as exits to an outdoor courtyard. The floor was coated with an epoxy coating that did not hold up to the daily wear of the 850 students traversing the corridor or thorough cleanings.
Recognizing the need for a durable yet green solution, the school contacted SPS and the Tstrata H (Coated Flooring System) was selected to repair the floor.
SPS began the repair project with surface preparation that required removing the old coating in some areas. Although SPS had a very short time frame in which to complete the repairs -- all repairs had to be completed over the summer break -- this did not prove to be a challenge as SPS was able to complete the majority of the repairs in a mere three days. Adding further appeal to floor, SPS incorporated the school's logo, a wolf in a glow-in-the-dark material, as well as burgundy, dark gray and white flecks to match the school's colors. To meet building code requirements, reflective tape was used for aisle markings. School officials are extremely pleased with the results of the customized, easy-to-clean and durable floor system.
"Tstrata offers many unique benefits to a variety of different markets," said John Friedel, Marketing Manager at Structural Preservation Systems. "With a non-intrusive application process and no Hazardous Air Pollutants (HAP) or Volatile Organic Compounds (VOC), Tstrata can be installed without major or costly disruptions to daily operations, which is extremely important for educational and industrial facilities."
For more information about Tstrata, contact SPS at (410) 850-7000 or visit http://www.tstratafloor.com/