Case Study: RYDER TRUCKS
Core Testing, soluble salts, metal shake, floor prep and system selection.
Background:
A Heavy Truck repair. Facility, Ryder Trucks needed to repair and replace its deteriorating, slippery floor, with a non slip oil impervious floor coating system. The existing floor was high in. soluble salts and the top layer was composed of metal shake – an antiquated method that was used to make the top of concrete harder. The project was undertaken to enhance the facility’s safety and hygiene and environmental standards. The installation was managed and completed by NUFLORZ INC., a company specializing in industrial floor coatings for 30 years.
Project Details:
- Scope: Mill of the top ¼ inch of the existing concrete floor to remove the soluble salt build up and metal shake to create a warrantable surface that would receive a long-lasting floor system. This system included a three component Cementous urethane base layer, followed by two epoxy broadcast matrix layers, and the two final coats, one 100%. Solids epoxy, and one urethane.
- Timeline: Scheduled for completion in 2 weeks.
Issues Encountered:
- High soluble salt levels. Core testing. Determined that high soluble. Salts would prove. To be. A bond breaker for. And. Concrete. Coating system, this top layer of. ¼ iinch. Needed to be removed.
- Oil Saturated. concrete: Sections of the epoxy mortar began to chip and delaminate away from the concrete substrate.
- Slippery Finish: Some areas of the floor were worn and slippery presenting the potential for a slip fall accident.
- Uneven floor surface. The concrete flooring caused unsafe foot traffic, vehicle traffic and fork truck travel.
- Oil saturated surfaces. The concrete substrate was saturated with motor oil, coolent and automotive chemicals outside of the designed containment areas.
Analysis:
Upon investigation, several issues were identified:
- Improper Material selection: The original concrete cure and seal had long worn off and no longer prevented fluid penetration into the concrete. The floor was also slippery. Long term automotive repairs, drive traffic and wear deteriorated the concrete.
- Substrate contamination: The concrete was saturated with automotive fluids.
- Floor abuse: The facility floor was never designed to withstand. A heavy truck. Repair facility.
- Corrective Actions Taken:
- Mechanically remove the top ¼ inch of concrete from the entire floor surface: The soluble salts and metal located. At the surface of the concrete was shaved / milled off.
- Surface degreasing and preperation: The concrete was cleaned with an environmentally friendly degreaser. Once dry, a prepmaster 4430 was utilized to smooth the floor, the floor was then aggressively shot blasted utilizing a Blastrac 2020 global.
- Floor Application Procedures: NUFLORZ INC. utilized a Cementitious urethane nonslip coating system at ¼ “ with a. chemical resistant topcoat. This preparation process and flooring system will prevent the future safety, environmental and failure concerns.
Outcome:
After following the appropriate floor preparation determined by core testing, the new high performance floor system designed for this environment was a success. Nuflorz implemented the corrective actions, and the resinous floor was successfully installed. Ryder Trucks reported increased satisfaction with the quality of the finished floor and observed ease of maintenance, no automotive fluid penetration through the system and a brighter work environment.
Lessons Learned:
- Core testing offer long lasting solutions: The correct floor system for the job can be. Determined with research. In some instances, core testing will offer the information. Needed to determine the correct poured flooring system.
- Install the right system for your environment: Paying attention to the needs of your people and the impact of your processes will lead you to the floor system that will serve you well for years.
This case study highlights the importance of thorough investigation, preparation, choosing the right products application, will ensure the success of a poured resinous epoxy flooring installation.