Electrostatic Painting Guide

Why Restoration With Electrostatic Painting Makes Sense

The most common places you might see an electrostatically painted surface include offices that use metal furniture as well as workplaces, gyms and schools with locker rooms.

Other places and items that can benefit from the advantages of the electrostatic painting process are:

  • File cabinets and storage shelves in large offices, storage facilities and retail stores
  • Exterior metal walls on commercial or industrial buildings
  • Fences and railings at historic landmarks, public recreational areas or amusement parks
  • Tubing for air ducts in commercial, industrial or school and other public buildings.

Commercial painters and electrostatic painting equipment manufacturers often refer to the device designed to atomize and spray the paint as a “sprayer” or “paint gun.” That’s because it’s ergonomically designed to fit in your hand like a gun.

What Is Electrostatic Painting?

what is electrostatic painting

Electrostatic painting is a process that uses specialized equipment to electrically charge and fluidize powdered pigment, then spray the particles as a coating onto a surface.

Classified as one of the “dry painting” systems of the powder paint it uses, the electrostatic painting process eliminates volatile organic compounds (VOC’s), hazardous pollutants (HAP’s) and solvents that are often found in other painting processes.

The electrostatic charge used in this painting process acts in two ways:

  1. It causes charged powder particles to behave like a liquid as they move through the air and land on the targeted surface.
  2. It facilitates attraction of unlike charges to each other. As positively charged particles seek the nearest ground, a mutual pull connects them, then bonds the coating to the grounded surface on which it’s sprayed.

The bonded coating made possible by the electrostatic painting process protects the surface underneath from corrosion that may be caused by moisture and oxidizing elements in the air. A high-quality finish restores the appearance to like-new condition.

For porous substances, like wood, the electrostatically coated surface can protect against moisture that attracts mold and fungus and can cause rot. On projects for which wood, plastic or another conductive, more negatively charged material is the target, special prep steps may be needed to ensure proper coating and a quality finish.

A Brief History of the Technology

history of electrostatic painting

Electrostatic finishing was founded in 1931 by Harold Ransburg, when, as a young man, he had to leave university studies to help his father’s business, Harper J. Ransburg Co. in Indianapolis, IN. During Harold’s work of painting stoneware and metal housewares, he experimented with equipment known to charge paint particles, and developed a system of electrostatic painting called the “No. 1 Process.” The process was widely used for painting of munitions and supplies during World War II.

As he continued experimenting, Ransburg learned he could negatively charge the atomized paint particles and also charge the item to be coated — or make it a neutral ground — creating an electrostatic field. This field then pulls paint particles to the item. Through innovation, Ransburg developed the No. 2 Process in 1948 and introduced a spray gun for that process in the mid-1950’s. The electrostatic painting process and equipment became more widely used in the 1960’s.

Advancements, including applications outside of painting, continue today. Commercial and industrial businesses, and institutions like schools, hospitals and governments, can benefit from electrostatic painting technology and processes that have been refined for more than 80 years. At Alpine Painting and Restoration, we use this dependable process to make your projects the best they can be.

How Does Electrostatic Painting Work?

From the start to the end of the electrostatic painting process, the operator uses the specialized equipment to atomize the paint and control the connectivity and flow between it and a grounded target.

how electrostatic painting works

To receive a charge and be electrostatically attracted to its surface target, the conductivity and resistivity measures of paints used should be known. Electrical resistivity represents a measure of how strongly a material opposes the flow of electric current. Paint with a low resistivity readily allows the movement of an electric charge.

Conductivity represents the reciprocal quantity to resistivity and a measure of a material’s ability to conduct an electric current. For some projects, water-based paints may be too conductive and not used with electrostatic painting equipment.

In powder coatings, conductivity agents are not needed as much because the electrostatic paint gun nozzle atomizes the particles. Fewer conductivity agents contribute to a reduction or elimination of pollutants.

The Locker Target Example

As an example, let’s look at a project for which you would hire a painting contractor like us to complete — restoring lockers in a high school gymnasium locker room. We would refer to the lockers as the “target” on which the paint will be sprayed.

Before spraying, we will complete preparations typically done to surfaces that will be painted. For metal surfaces, this includes steps to remove dirt, contaminants, loose paint, rust, scratches or graffiti.

For every project, prep work also includes mixing the paint according to instructions provided by the electrostatic painting equipment manufacturer. Adherence ensures proper atomization, viscosity, conductivity levels, even application and safety.

When we start the painting process, we will use the paint gun equipment to charge the paint particles. Electrostatic painting equipment manufacturers refer to this as atomizing the paint. Scientists and engineers refer to the process as ionizing the paint particles.

The charged particles of the paint gun create an electrostatic field between the paint gun nozzle and the grounded target. Principles of electrostatics come into play. With the paint particles atomized, the grounded locker target pulls the oppositely charged particles to it. We use this attraction to guide the flow of the charged particles through the paint gun nozzle.

The paint particles land and bond only to the open surface area that’s grounded. As the particles coat the target, the charge dissipates and returns to the power supply through the ground, completing the electrical circuit. Because the charge of the target locker surface changes once the bond between the unlike charges occurs, the coated area stops pulling paint particles to it.

The electrostatic process is completed with an even, high-quality application of the coating. Most of the atomized particle spray from the paint gun lands on and bonds to the locker. Engineers call this “high transfer efficiency” and have measured this paint application efficiency rate at over 90 percent when optimized.

How Can a Painter Be That Accurate?

With the right tools, a commercial painter can use electrostatics to influence the path of the paint because the particles are small enough to be controlled by the charge from the paint gun. At indoor project sites, the painter has added influence to minimize air currents that might interfere with paint particle flow, and, therefore, has more control over how fast the particles move to the target. This gives the electrostatic paint gun operator the power to optimize paint and time use.

electrostatic paint choice

The painter’s selection of paint also contributes to the effectiveness of the electrostatic painting system equipment, as some particles accept an ionizing charge more readily than others. Equipment manufacturer engineers consider this when designing and producing the products, and they will recommend the products that meet the highest transfer efficiency standards while balancing finish quality standards.

What Is Wrap or Wraparound?

Electrostatically charged paint particles are so attracted to the grounded target that they tend to coat the side, edge, corner and backside surfaces that aren’t facing the atomizer. This tendency reduces touch-up and clean-up labor, and it increases the ratio of surface covered to paint volume.

What Equipment Does Electrostatic Painting Require?

Equipment required to paint items brought to an electrostatic painting facility differs from equipment required to go to a client’s location where on-site work will be completed and proper grounding safeguards applied.

Here we focus on equipment for commercial, industrial and institutional painting or restoration projects that must be completed at the location of the items to be painted. The electrostatic painting process equipment for this purpose must be a portable system that includes the following:

  • Paint gun with atomizer: The main piece of equipment for electrostatic application of paint. Over time, paint guns have become lighter in weight, optimizing their portability to work at client sites. Most important to the design of the gun are its ionizing apparatus and sprayer with a resistive, high-voltage circuit that builds in safety. These may be automatic or manual. This design works ergonomically to make finger control of the on/off switch and handling of the spray nozzle simple. Many paint gun designs integrate voltage control to allow the gun operator to easily adjust between a range of voltage levels.
  • Bell: At the end of the nozzle, the bell controls the delivery rate of the paint and the paint application rate. The bell can be switched out depending on the size and shape of the objects to be painted as well as other requirements of the specified project.
  • Tank: The tank holds the paint until it’s pushed up through the fluid hose to the paint gun. Tank sizes range in gallon capacity, allowing electrostatic paint system operators to choose a reservoir size that fits the project size, mobility needs and space limitations of the work site.
  • Compressor: This system component controls the mechanism that pushes the paint from the tank to the paint gun. Compressors include pollution control functions and safety features.
  • Power supply for the paint gun and compressor: This is basically a generator with a series of high and low voltage power settings for electrostatic paint applicators, adjustable to the operator’s use of a gun or industrial rotary atomizer. The power supply controls the transfer efficiency of the paint gun while maintaining safety. Display panels on the power supply unit allow the operator and worksite manager to easily monitor and adjust voltage or current. Safety features include displays that indicate cable faults or overloads, and a reset switch.
  • High voltage cable: As part of the electrostatic painting system, an integrated part to ensure safe operation.
  • Fluid hose: Connects the compressor to the paint gun, serving as the channel through which the paint particles travel before atomization.
  • Cart: Designed to organize the system components, the cart allows for easy portability of the equipment to and at the work site. Like other components, the design integrates system safety.
  • Accessories: These come in the form of finishing applicators that can be attached to the end of the paint gun nozzle. Painters will use these according to the project needs and worksite specifications.
  • Multi-valve assemblies: When needed, multiple valves make changing fluid supply easy for projects requiring multiple colors or application of various coatings.
  • Flow control systems with monitors: These allow operators to more efficiently control paint usage.

Manufacturers of electrostatic painting process equipment sell the components as integrated systems. This ensures reliable operation, quality finishes and safety. At Alpine Painting and Restoration, we use Ransburg equipment to ensure quality control and that your project comes out smoothly.

Top Five Benefits of Electrostatic Painting

The benefits of electrostatic painting come from the technology that leverages electrostatic principles. A combination of paint application equipment and paint formula technology has revolutionized our ability to restore commercial, industrial and institutional assets.

Because of innovations in technology over eight decades, you can realize the following benefits in choosing restoration over discarding or replacing valuable or expensive items:

1. Reduction in Wasted Paint

reduce paint waste through electrostatic painting

When you hear painting and restoration professionals talk about the electrostatic painting process, you’ll hear them often refer to the paint as “coating.” When you watch the electrostatic painting process, and how the paint particles wrap to the surface as the sprayer moves around the corners and curves, you’ll understand why.

It’s the wrapping quality the paint takes on that maximizes the amount of pigment that attaches then bonds to the surface and reduces the amount of paint that misses the target. The transfer efficiency, or percentage of the paint used without waste, is a high percentage of the amount loaded in the sprayer.

That waste reduction could translate to savings of anywhere between $25 and $75 per gallon of paint, depending on other high pressure or air assisted method the electrostatic coating process replaces.

2. A Smooth and Seamless Electrostatically Painted Surface That Looks New

The quality of finish achievable with electrostatic paint application can truly make a facility with some years behind it look new

3. Fast Painting and Dry Times Mean Shorter Down Time for Your Business

Similar to air spraying methods, the electrostatic process makes paint application fast. Electrostatically applied paint dries faster than wet spray methods and doesn’t require high-heat ovens. You no longer have to wait for weeks with rooms temporarily out of use or for fumes to dissipate. Normal business can resume within days.

4. A Durable Finish for Your High-traffic, Heavy-Duty Use

The bonding properties possible with the electrostatic process make for strong protection against corrosion, weather wear and heavy use. Durability can be especially valuable where your assets may be exposed to indoor or outdoor humidity and moisture.

5. Overall Savings in Money and Time

The next time you’re considering discarding items that are still functional but “look old,” consider having a contractor that specializes in electrostatic painting take a look. You may find that restoration is a viable option. The right coat of paint could extend your original investment and protect a still valuable item for years.

Trust Alpine Painting and Restoration for Your Facility Painting Needs

When choosing a painting and restoration contractor for your commercial and industrial needs, you’ll want one whose business longevity reflects the enduring trust of satisfied clients. You should also choose a contractor whose electrostatic painting equipment operators are knowledgeable in all aspects of the process, equipment and materials, and disciplined in their safety practices.

For restoration and painting, and especially budget-conscious, safety-imperative methods like electrostatic painting, the level of trust you’ll need is high. Alpine Painting and Restoration has been delivering safety at the worksite and high-quality final results to satisfied customers since 1990.

We’ve seen many technologies and methods come and go for almost three decades now. Today’s electrostatic painting, which has been around for the last decade, may improve or eventually be replaced by another technology or method — but our approach will always be to apply current methods and technologies for durability, longevity and budget. Our customers will always see that in the quality of service and safety we deliver on-site, including our safe use of equipment and grounding practices.

To learn more about commercial and industrial electrostatic painting for commercial and industrial assets such as building interiors, exteriors and equipment, contact us online or call us at 215-348-4410. We can show you samples of the quality surface protection, durability and aesthetic presentation electrostatic painting delivers for your most valued assets.

Commercial Painting Facts

Commercial Painting Facts

If you are in need of high-quality commercial painting in the Pennsylvania or New Jersey area, you can rely on Alpine Painting and Restoration to get the job done right. Perhaps you don’t know if you are in need of commercial or industrial painting. What is commercial painting, exactly — and what is industrial painting? Are commercial painting techniques different from industrial painting techniques?

Commercial Painting Definition

If you have a business with a physical location that needs a new paint job, you are in need of commercial painting. Whether you want to rebrand your store front or you want your company’s offices to have a bright new look, you want to call in a commercial painter.

The appearance of your business is extremely important. If your physical location is customer facing, a stylish, fresh, up-to-date paint job tells potential consumers you take your products or services seriously and you are ready for business. If your business location is primarily for employees, a great commercial paint job can improve morale and help workers stay focused.

Industrial Painting Definition

When we talk about industrial painting, we are usually talking about facilities that are a step removed from the public, such as warehouses or manufacturing plants. The needs of these types of facilities are a little different, but the techniques are similar.

A warehouse or factory with chipping paint can not only be a safety issue, but it can also create a negative impression to potential partners, vendors or even customers who might happen to come by. Even if you’re not worried about such visitors on a daily basis, giving your warehouse or factory a good cleaning and painting can tell your workers you care about them and about the products that move through the facility.

Alpine Painting and Restoration for Commercial Painting in PA and NJ

At Alpine Painting and Restoration, we have the personnel and equipment to thoroughly clean and prepare all surfaces that require painting, and perform a clean, accurate paint job that will have your facility looking great. We have painted retail stores, hotels, restaurants, factories and warehouses, and we have countless testimonials from satisfied businesses backing up our claims regarding the high quality of our work. Exterior or interior commercial paint jobs, big projects or small, we do it all with professionalism and precision. We’re not satisfied until we know you’re satisfied.

If you have a business in Pennsylvania or New Jersey that needs painting, what are you waiting for? We’re ready to make your business look the best it’s ever been. Contact Alpine Painting and Restoration today for more information on complete painting services for your business.

Common Epoxy Floor Problems

epoxy floor problems

Epoxy Floor Problems

Epoxy is one of the best floor finishes for commercial and industrial applications available today. Because epoxy is so durable as well highly attractive, epoxy floor finishes are in high demand. Epoxy is also affordable considering the long-term performance it offers. But epoxy floor problems do happen, especially when improperly applied.

epoxy flooring appearance

Epoxy finishes usually appear on concrete floors where high traffic volume, clean conditions and excellent appearance are necessary. Many facilities that benefit from epoxy floors include automobile showrooms, pharmaceutical manufacturers, laboratories, food and beverage processors, aeronautic maintenance and even general purpose warehouses. The cost per coverage return on epoxy makes it the ideal floor choice for low maintenance and easy cleaning.

Many people make the mistake of thinking epoxy is just a type of paint. It’s not. While epoxy is a coating that goes over an existing flooring subsurface, it’s actually a blend of components that chemically react to produce a unique product with strength and durability properties that are nearly impossible to match.

It’s misleading for suppliers to brand products as “epoxy paint.” This is where do-it-yourselfers get in trouble. Epoxy floor coverings are tricky to work with and best left to professional applicators. Otherwise, there’s bound to be trouble such as bubbles in the epoxy floor coating and epoxy floor blistering.

People often ask how to repair epoxy floor coating and “can I epoxy over epoxy?” The truth is it’s just not that easy. The key to having a successful epoxy floor application doesn’t lie in one simple trick. It’s a highly variable combination of techniques and conditions that professional epoxy floor coaters have perfected. To understand how to work with epoxy, the first thing you need to know is what exactly it is.

What is Epoxy Floor Coating?

Epoxy is a two-part, thermosetting product composed of epoxide resin and a polyamine hardener. The resin gives an epoxy finish its depth and color character. The hardener component acts as a catalyst, giving it strength. When carefully mixed at precisely the right ratio, a chemical reaction occurs.

Epoxy doesn’t dry like paint. It cures. The curing process creates polymer structures that closely cross-link during an exothermic process to give an epoxy floor finish superior durability and strength. The final product is unique. Epoxy is like no other as long as it’s properly prepared and applied.

Epoxy chemical knowledge and excellent commercial products have been around for years. Since the internet and the explosion of renovation shows, however, epoxy finish problems have become more common. True epoxy finishes are two-part procedures, except in certain cases in which a third aggregate component provides additional grit for improved traction.

“Epoxy paint” is a marketing term that manufacturers and suppliers invented to satisfy a high demand for DIY and home epoxy floor treatments. These one-part paints do contain some epoxy resin but don’t have anywhere near the amount of solid content that commercial two-part epoxy products have. Solids give epoxy finishes their thickness.

Top quality epoxy resin products contain a high percentage of solids that stay on the floor after application. A rating of 100% solids means that all of it remains in the finish after curing. That creates a thick, sturdy and durable base. 50% solid ratings found in inferior products result in half of the product being a solvent that evaporates leaving the floor finish half as thick as professional materials.

roller applied epoxy flooring

For example, roller-applied epoxy containing 100% solids leaves a wet film thickness (WFT) of approximately 10 millimeters. When it cures, that thickness stays at 10 millimeters. The same roller-applied technique with 50% solid resin goes on at 10 millimeters but cures to a final finish of only 5 millimeters. That is a lot of finish lost due to lack of product knowledge likely misguided by an attempt to economize.

Like any other product, you get what you pay for with epoxy floor finishes. This applies to hiring an applicator and their level of care in subsurface preparation, product mixing and application procedure. Correctly applied, epoxy finishes have tremendous benefits.

  • Durability is a primary advantage. Epoxy floors are sturdy, and they last for ages.
  • Strength is an extenuation of durability. Epoxy is extremely resistant to damage.
  • Because epoxy material is tight and non-porous, it’s easy to clean, making maintenance a breeze.
  • The aesthetics of epoxy are excellent. Epoxy finishes come in a wide range of color and sheen.
  • Epoxy comes in a variety of different types. Additives include metal flaking and clear coating.
  • Safety is a top benefit of epoxy floors, which can create non-skid and non-slip surfaces.
  • Using a high-gloss finish in your epoxy flooring systems will yield exponential increases of LRV values ( light reflectance) which thereby will reduce overall energy usage from overhead lighting fixtures and also will increase productivity.
  • Epoxy is fast-curing and quick to apply, which means that the shutdown required to install it is minimal.
  • Cost-effectiveness is another huge benefit. Epoxy lasts for years and provides an excellent return on investment.
  • Chemical resistance is a vital aspect of surfaces at industrial sites. Epoxy is the perfect choice for places that use chemicals, which might spill on the floor.

With so many benefits streaming from epoxy floor coats, it’s unfortunate that they can come with problems. But they don’t have to. Epoxy floor coatings that are professionally applied are problem-free, provided the applicator knows what they’re doing.

Common Epoxy Floor Problems

Virtually all problems with epoxy floor coating originate from one source – the applicator. Unqualified epoxy floor applicators fail to accurately assess site specifics like temperature, moisture and airflow. They often fail to prepare the subsurface to make sure the epoxy coat will bond and to blend the exact ratio of resin and hardener, which is critical to success. They might also neglect to mix the two-part epoxy products to ensure correct air entrainment. And unknowledgeable applicators fail to follow time-critical steps that result in a professional, long-lasting finish.

The harsh reality of epoxy floor finishes is that botched jobs are almost impossible to touch up. In most cases, there’s no alternative to stripping the faulty finish and starting over. That’s a lot of money wasted on time and materials that could’ve been saved if only the applicator knew their stuff.

Professional epoxy floor finishers are often called to assess a newly-placed floor showing problems. Most experienced floor finishers who regularly work with or specialize in epoxy see the same issues time and time again. Here are the most common epoxy floor problems and the diagnosis of their causes:

Bubble formations are by far the most common problem with epoxy floors. Usually, bubbles are only pinhead-sized and appear in clusters called honeycombs. Mistakes mixing the correct ratio of resin to hardener can lead to air entrapment or entrainment, which causes epoxy floor bubbles.

Excessive mixing such as using a power drill and a spiral paddle at high speeds also produces bubbles. You can easily avoid this by using a wide mixing blade set at a low 300-500 rpm rate and slowly circling the mix in a large container. Once air-entrained bubbles are set in an epoxy mix, they’re next to impossible to remove. You’ll have to discard the mix because if you use it on the floor, bubbles will appear.

Another source of epoxy bubbles is temperature differences. The substrate, like a concrete surface, needs to be at a temperature that’s compatible with the epoxy mix. The same goes for resin and hardener temperatures. Excessive temperature variation leads to trapped air that tries to equalize. This results in very visible bubbling and rejected work.

Blisters and craters are the second most common epoxy trouble. Blisters are large bubbles that contain trapped air. Craters are the opposite. They occur when bubbles pop and leave an indentation in the epoxy surface. Improperly prepared concrete that’s porous and contains air can lead to outgassing from the subsurface, which, in turn, causes large blisters and craters.

Air trapped in concrete voids reacts when the freshly covered epoxy begins its curing or exothermal action. The chemical reaction creates heat. This releases moisture in an air pocket making it expand. This forces air to the surface where it forms either a blister or a popped crater.

Film and flow appearance Film and flow appearance stand right out in a bad epoxy floor job. The finish appearance is dull and uneven. This happens when the epoxy coat is applied too cold or too hot. It also occurs when excessive airflow blows over a curing surface.

how temperature affect epoxy flooring

Preventing film problems is easy. Epoxy is highly temperature sensitive, so you can apply it when both the mix and the subsurface are between 60°F and 85°F. Temperatures above and below those are sure to cause a dull film to appear on the outer surface.

Flow is another easy problem to prevent. Flow problems appear as wavy irregularities on the epoxy surface and are very noticeable under certain light conditions. The usual culprit is a ventilation fan set in place to control hardener fumes or a large opening allowing wind to blow across the curing surface.

Poor adhesion and peeling can have many causes. This fatal flaw is always due to an inexperienced or careless applicator. Peeling and poor adhesion come from:

  • Poor subsurface preparation
  • Contaminated materials like grease, oil and solvent not being removed
  • Incorrect mixing ratio of resin and hardener
  • Improper mixing techniques
  • Wide temperature variations
  • Moisture trapped in the subsurface

Other Common Epoxy Floor Problems

Not all epoxy floor problems are as noticeable as peeling and blistering. Other common problems regularly occur from lack of applicator detail and precautionary steps. Experienced epoxy floor workers know how to prevent these other common issues.

  • Tacky surfaces and soft areas result from improper mixing and temperature variation. The primary cause is the lack of a catalyst occurred during curing leaving a weak, uncured and tacky surface. The solution is to make sure to use exactly the right ratio of resin to hardener.
  • Surface blushing shows as high and low sheens in the finished product. When amine chemically reacts in the blended resin, surface blushing may occur. Excessive air moisture is another common culprit. It can also come from application in an ambient temperature that’s too low. You can correct this by using heaters or dehumidifiers.
  • Lack of uniformity comes from applicator technique rather than from bad mixes or conditions. Epoxy floor finishes are finicky to apply due to temperature, time and resin viscosity. An inexperienced or careless applicator can leave streaks, dry edges and highly-noticeable roller marks.
  • Fish eyes are imperfections usually caused by residual silicone or oil that wasn’t thoroughly removed during surface preparation. They can occur due to placing a top coat over primer that hasn’t yet cured. Proper and careful prep can prevent fish eyes.
  • Lumps, globs and bumps in the top coat come from poor mixing, improper subsurface cleaning or using application equipment that leaves lint behind. Once these imperfections set in, the only solution is removing the epoxy finish and starting over.

dull epoxy flooring

  • Dullness usually results from excessive humidity, which is anything over 60%. Dull, lusterless floors can also result from condensation covering the floor before it properly cures. This is a common problem during rainy weather or highly humid periods.

How to Avoid Epoxy Floor Problems

When so many things can go wrong with an epoxy floor finish, it’s a wonder any inexperienced person would try this on their own. Epoxy floors are cost-effective over years of trouble-free service — provided a skilled applicator who is aware of common problems and makes sure to correctly prepare the surface applies them properly. But epoxy floors can be very expensive when an unskilled applicator leaves a finished product in a mess.

The simplest way to prevent problems with an epoxy floor coating is to hire a professional who has the experience and knowledge to apply your epoxy finish, so it’s problem-free for its entire life. Professional epoxy floor applicators have the training and tools to do it right the first time. They know how to assess your site conditions and how to prepare all types of subsurface properly.

Professional applicators know exactly how to mix the correct resin/hardener ratio, and they know the precise mixing methods needed to prevent air entrapment and lumps. They anticipate and control temperature and humidity conditions to avoid dull, tacky and blistery finishes. And epoxy floor professionals have advanced and skillful application techniques that leave the finished floor streak-free.

Why risk ruining an expensive epoxy floor finish by leaving it to an amateur or attempting a do-it-yourself project? The simple solution for success is to call Alpine Painting and Restoration. We’re professionals with 27 years of epoxy floor finish experience in commercial and industrial applications.

We’re committed to quality results with a high emphasis on long-term preservation. We serve the tri-state area with a wide variety of epoxy floor finish services and are highly familiar with the latest epoxy products and application procedures.

Don’t leave your epoxy floor work to an amateur. For guaranteed professional results, call Alpine Painting and Restoration today at 215 348-4410 or contact us online.

Adventure Aquarium Project

Back in May our firm was contacted by Herschend Entertainment, the management company of the Adventure Aquarium in Camden, NJ, for the execution of high-performance coatings that were immersible for the newly fabricated and refreshed penguin exhibit.

This presented unique challenges because we had to install high-performance coatings that gave the illusion of being natural rock face and cluster that mimicked the penguin’s natural environment. After consultation with Tnemec Coatings Company, it was determined that we should use their water based immersion grade high performance 100% solids epoxy coating system ( Product Designations 27WB) in a multiple of ten different colors that had to be overlaid on each other to bring about the natural look of the fabricated rock faces.

The accompanying pictures will illustrate the gunite fabrication of the boulders and shore line rock formations. Preparation methodology was hydro blasting with mild acidic solution, neutralization with sodium hydroxide based detergent, installation of polyamytal-amine epoxy solvent based base coat to provide maximum adhesion to substrate (Tnemec Product Designation N69) and two 6 mil top coats of the 27WB product to provide a solid basilar background color and final top coat installation of various color multiples and optics to provide the final finished look prior to the filing of the penguin pool.

We are happy to say that the project came off without a hitch or any delays which was very challenging due to an extraordinarily wet spring and the aquarium was able to meet the grand opening date of the newly refreshed penguin exhibit. Please feel free to review the following images.

Project Images

penguin project special coatings penguin aquarium project      

Dejana Truck & Utility Equipment Restoration

Recently, our office received a phone call from a Project Manager for a high powered, light truck retro fit and parts manufacturing company and installer. He indicated to me that they just made settlement on a new building asset and space in the New Britain/Bucks county area to facilitate the company’s expansion focus; the former Skee-Ball manufacturing facility.

The facility had not seen any real attention either aesthetically, or from an asset preservation standpoint, in many, many years. To be quite honest, the facility was looking pretty haggard and tired. The Vice President of Operations of Dejana Truck & Utility Equipment asked me to visit the site and offer any pertinent suggestions, as well as provide a quote to transform the exterior of the building from the tired old girl that she was into a 21st century service facility that would accurately reflect the company colors, as well as the standard company visual that they are known for.

The accompanying images will illustrate the before, during and after images of the project. A capsule overview of the projects methodology is as follows:

  • Waterblast entire exterior with high strength caustic detergent to remove all oxidation and ancillary surface contaminants
  • Inspect all corrugated panel, and fasteners.  Replace and re-fasten all compromised fasteners
  • Spray apply one heavy bodied coat of rust inhibitive corrosion control epoxy primer
  • Spray apply ultra-high performance acrylic finish to all prime coated metal to accurately mimic a factory finish

1st-image 2nd-image

  • All split faced block was water blasted, patch pointed where necessary and re-caulked where necessary (failed expansion joints)
  • All block walls received one coat of 100% acrylic cinder block filler primer coating
  • All prime coated cinder block received two coats of Pearl Gray high performance acrylic masonry coating and finish

4th-image exterior-after

As illustrated above, you can see that the transformation of the asset was nothing less than dramatic.  The deep blue color, as well as the Pearl Gray, is Dejana Truck & Utility Equipment’s corporate colors which are universally applied through their many branches.

Industrial Flooring Remediation

Recently, our office received a phone call from a potential client that was extremely distraught about some recent work that was performed on his new facility expansion. The client is a local sign and graphics company that specializes in vehicle and banner advertising for a plethora of companies local to my firm. As their business was growing, there was a real need for additional space to accommodate their installs for their clients, as well as the growth of their company. The client scrimped and saved for the better part of 36 months to accommodate the cost of the 5,000 square foot expansion. In an effort to keep costs down, the client acted as his own construction manager. All was going well until the concrete contractor, that was hired to place and finish the concrete, performed substandard work. This caused great distress to the client, because in order to install the vinyl graphics on larger vehicles (box trucks, triaxles, etc.), his wife, as well as his staff, has to utilize electric scissor lifts to facilitate the installs. This was now at risk because the floor was drastically uneven and unlevel, so much so that using lift equipment would create a precariously dangerous situation posing great physical risk trying to do these installs.

Unfortunately, the client went back to the concrete contractor and tried to plead his position, but, as is so often the case, once the contractor was paid, the contractor had no intention whatsoever to remediate the situation. We were asked to come down and assess the situation and give our opinions on how to fix it. Upon visual inspection of the slab, I was appalled at the amateurish ineptitude of the install by the contractor. And I was quite concerned for the client and his wife because this is a small family business. They were inconsolably upset at the possibility that they may have lost a huge sum of money as part of this construction. I assured them that we would pursue whatever methods and methodology at our disposal to get the floor into a workable and safe condition

We developed the following plan to remediate this floor and make it safe:

  • Aggressive mechanical scarification of the concrete that was above the natural level line
  • Diamond grind entire floor with prep master equipment to smooth out scarified areas
  • Bring in temporary, three phase generator power to support and power up our grinding equipment
  • Repair all shrinkage cracks and spalls with epoxy mortar

Initial Scarification

Illustrates severity of the uneven floor

Typical scarified profile

Image illustrates clearly the ponding situation

  • Grind down repairs as necessary
  • Install penetrating epoxy primer to prepared floor
  • Install high solids epoxy intermediate coat to prime coated floor
  • Install high solids epoxy background color to intermediately coated floor

Portable 3 phase generator to support our grinding equipment

Diamond grinder to level out floor and provide proper surface profile

Properly prepared floor

Penetrating primer applied

 

  • Operator broadcasting multi-colored blended flake to entire freshly coated floor
  • Operator installing a clear urethane lock down coat to permanently seal flake into coating system
  • Final finish of completely remediated floor

Intermediate coat applied

color applied to prepare for flake broadcast

Close up of flake broadcast

Finished floor with clear coat installed

 

I am pleased to report the floor has been in service for the better part of 6 months with absolutely zero issues and has exhibited an easy to maintain flooring surface concerning housekeeping and preservation of aesthetic. And the new shop shows well on customer visits and new customer tours. Most importantly….SAFE to work on. To learn more about our commercial and industrial flooring services, click here.

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