Flooring Case Study: Glass Manufacturer

Case Study: Corning Science Center

Failed Initial Epoxy Floor Installation by prior contractor.
Corrective Action taken by NuFlorz.

Background:

A Research and manufacturing facility, Corning Science Center Campus, elected to install a poured flooring system in their facility to improve durability, ease of maintenance.  and a long term solution to failing poured floor. The project was also undertaken to enhance the facility’s safety and hygiene standards, as well as to create a more aesthetically pleasing environment. Following concrete core testing and analysis by the Nuflorz team, a procedure and product recommendation was submitted to the General Contractor. Nuflorz was not initially awarded the project. 

Shortly after the new installation, failure of the system was obvious and unacceptable to the owner. The floor product was delaminating, and bubbles were appearing 30 days after completion.  Nuflorz was called upon to assess the problem, propose a solution,  and install the original specified system that was specified. 

Project Details:

• Scope: Specify a product and resinous floor system, prepare the concrete, and installation of a 5-layer poured flooring system. Provide a fixed price.
• Timeline: Scheduled for completion in 8 weeks, second and third shift.

Installation Failure:

1. Bubble Formation: Shortly after the topcoat application, bubbles began to form on the surface. This was observed in several areas of the floor.
2. Peeling and Delamination: Within a few weeks, sections of the epoxy began to peel away from the concrete substrate.
3. Uneven Finish: Some areas of the floor exhibited an uneven finish with visible streaks and color variations.

Analysis:

Upon investigation, several issues were identified:

1. Inadequate Surface Preparation and research: The concrete surface was not removed to a level acceptable to receive a poured floor system. The top 3/16^th of an inch of the concrete surface required removal to eliminate the bond braking materials that would lead to a coating failure. 
2. Moisture Issues: The bubbles were attributed to moisture trapped beneath the epoxy layers, either due moisture in the concrete, and build up of the soluble salts.
3. Inadequate materials. The moisture mitigating primer that was recently installed, was not adequate.
4. Lack of sufficient topcoats: The topcoat was not uniform due to a lack of skilled labor and not enough topcoats.

Corrective Actions Taken:

The procedure and product recommendation that were originally proposed, was re submitted to the owner for review and accepted. The original concrete core testing and analysis completed by the Nuflorz team was approved and Nuflorz moved forward as follows:

1. Surface Preparation: The failing recently applied floor system was removed using various methods including, milling, PCD grinding and shot blasting. Concrete shaving was also required to remove the soluble salts. The concrete surface was cleaned, imperfections were repaired. 
2. Base Coat: A Cementitious Urethane base coat was applied to bond to the substrate surface.  
3. Matrix layers Application: A custom color decorative flake was broadcast into Methyl methacrylate MMA liquids. A double broadcast was installed. 
4. Topcoat Application: Two orThree topcoats were installed at the owners request to achieve the desired texture for the different workspaces. 
5. Testing: A third party was enlisted to complete bond testing utilizing the pull test method. These results of Nuflorz preparation revealed a new record of pull test resulted upward of  12,000 PSI. 

Outcome:

After implementing the corrective actions, the poured floor was successfully reapplied. The final result met the facility’s durability and aesthetic requirements. Corning reported increased satisfaction with the quality of the finished floor and observed improved maintenance and safety conditions with no failures.

Lessons Learned:

1. Thorough Surface Preparation and core testing is Crucial: Proper surface preparation is essential for ensuring strong adhesion and preventing issues like peeling and bubbling.
2. Adherence to Manufacturer Recommendations and Specifications:  Application according to manufacturer guidelines are critical to achieving a long lasting consistent and high-quality finish.
3. Monitoring Environmental Conditions: Paying attention to subsurface conditions such as vapor drive and soluble salts will prevent common problems associated with resinous flooring installations.
4. Ongoing Training: Regular training for installation teams helps maintain high standards and addresses emerging issues effectively.

This case study highlights the importance of thorough preparation, precise application, and continuous improvement in ensuring the success of poured flooring installations.