Ecoatings Newsletter Q2 2016

CONTENTS

IMPACT AWARD

ANTI-GRAFFITI COATING

2016 NEW PRODUCTS CORNELIA MARIE

STI AWARD

FOOD PLANT FLOORING

VIEW FROM CONCRETE BRIDGE

1 | sherwin-williams.com/protective

BRIDGE & HIGHWAY VETERAN

Q2 2016

EVENTS

Your Source For Coating Solutions

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e-coatingsolutions

CONTENTS

1.800.524.5979

EUROPE & MIDDLE EAST: +44 (0)1204 521771

IMPACT AWARD

NORTH AMERICA:

ASIA:

eCoating Solutions is designed and distributed by Sherwin-Williams Protective & Marine Coatings North America.

ANTI-GRAFFITI COATING

+8621 51587798

2016 NEW PRODUCTS CORNELIA MARIE

It also means that we deliver on time, every time from 4,000 company-owned distribution points worldwide.

Leave nothing to chance. Your single source of supply. Sherwin-Williams.

Protective & Marine Coatings

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©2016 The Sherwin-Williams Company

EVENTS

To learn more, visit us at www.sherwin-williams.com/protective

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That’s where 150 years of coatings industry experience comes in. Add to that a NACE-trained workforce with a combined 3,700 years of experience in corrosion control, the market-specific knowledge that our experts provide to evaluate, recommend and deliver the highest-performance coatings and linings that protect our customers’ assets.

FOOD PLANT FLOORING

It starts with a complete line of time-tested, high-performance products and some of the most innovative technologies in the coatings industry. But we know that it takes more than product alone to be a world leader in protective coatings and linings. And so do the customers that rely on us every day as we help them protect their business.

STI AWARD

A complete line of products. Market expertise. On-time distribution. What else would you expect from a world leader in protective coatings, linings, and fire protection?

CONTENTS

contents

IMPACT AWARD ANTI-GRAFFITI COATING 2016 NEW PRODUCTS

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featured Contents

4

Impact Award

5 Anti-Graffiti Coating Showcase

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Food Plant Flooring

21

Contractor Profile M J Painting Contractor Corp.

2016 Calendar of Events

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The View From The Concrete Bridge

29

Sherwin-Williams Recruits Bridge & Highway Veteran

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BRIDGE & HIGHWAY VETERAN

23

VIEW FROM CONCRETE BRIDGE

STI Award

- Dura-Plate® 2300 - Dura-Plate® 6100 - Heat-Flex® 3500

EVENTS

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Cornelia Marie Case History

2016 New Products

FOOD PLANT FLOORING

12 Sherwin-Williams

Protective & Marine A Catch with Cornelia Marie Crew

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STI AWARD

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CORNELIA MARIE

Issue

CONTENTS

All submissions will be reviewed by an independent judging panel of water industry experts, who will narrow down the top 12 projects. Judges will then choose the winner, a runner-up, and an honorable mention.

Judges will include: Tim Greene – S&ME Coating Service Project Manager; Randy Nixon – Corrosion 4 | sherwin-williams.com/protective

For more information or to submit your project, visit

www.sherwin-williams.com/impactawards.

Required submission information includes: project name and location; owner, specifier, coating inspector, and contractor names; coating system(s) applied; date of project completion; the story/scope of the project; and a signed project release form.

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“The Sherwin-Williams Impact Award considers project types from all aspects of the water and wastewater market, such as water treatment, water storage, water transmission, sewer collection, and wastewater treatment, instead of focusing solely on highly visible structures,” Morris said. “This award also utilizes a panel of third-party judges who are recognized professionals in the water and wastewater industry to truly evaluate the merits of a project.”

VIEW FROM CONCRETE BRIDGE

“Water and wastewater infrastructure is essential to public health and the safety of the population along with being a critical component to economic growth,” Morris concluded. “The significance of this award is the consideration for the impact to the greater common good of the community served with regard to asset protection. The use of high-performance protective coatings to prevent or solve corrosionrelated problems is far more significant than what is identified through other programs today.”

EVENTS

Applications for the inaugural award are being accepted now through July 31, 2016, via the Sherwin-Williams Waterblog (http://sherwinblogs.com/impact-award).

The Sherwin-Williams Impact Award will be presented at the Water Environment Federation’s Annual WEFTEC Conference September 24-28, 2016, in New Orleans, Louisiana.

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Award entries will be rated on difficulty of the submitted project, challenges that were overcome, solutions provided to the owner, satisfaction of the outcome, and overall uniqueness of the scope and story for the project.

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“This award was created to recognize project excellence while highlighting the quality that SherwinWilliams products provide for all structures within the water and wastewater market segment, as well as the impact those products have in their communities with regard to public safety, asset protection, and life cycle improvement of infrastructure,” said Kevin Morris, Water & Wastewater Market Director, SherwinWilliams Protective & Marine Coatings.

STI AWARD

These experts include NACE-certified inspectors and instructors, SSPC Master Coating Inspectors and specialists, and AWWA chair and committee members – among many other distinguished affiliations. Their work encompasses corrosion and materials engineering, consulting, specification, testing, and inspection services.

CORNELIA MARIE

Recognized projects will include any water-related structure that is new, restored, and/or rehabilitated and has been completed using coating and lining materials from Sherwin-Williams Protective & Marine Coatings from January 1 through December 31, 2015.

Probe, Inc. President & Founder; Gregory R. “Chip” Stein – Tank Industry Consultants Managing Principal; and Larry Skip Vernon – Coating & Lining Technologies, Inc. President.

2016 NEW PRODUCTS

Sherwin-Williams Protective & Marine Coatings is pleased to announce its inaugural Sherwin-Williams Impact Award. The award program will recognize application contractors, specifiers, and owners for excellence on North American water and wastewater projects that have a compelling effect on the industry.

ANTI-GRAFFITI COATING

Award program to recognize project excellence using Sherwin-Williams Protective & Marine Coatings

IMPACT AWARD

SHERWIN-WILLIAMS ANNOUNCES ANNUAL IMPACT AWARD FOR WATER & WASTEWATER PROJECTS – APPLICATIONS BEING ACCEPTED NOW!

CONTENTS

FEATURE

IMPACT AWARD ANTI-GRAFFITI COATING 2016 NEW PRODUCTS VIEW FROM CONCRETE BRIDGE BRIDGE & HIGHWAY VETERAN

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“A partnership with Sherwin-Williams to use our Anti-Graffiti Coating presents a viable solution to beautify, preserve and protect communities,” said Danica Zeise, Sherwin-Williams Protective & Marine Product Manager.

EVENTS

During the Anti-Graffiti Coating demonstration, guests first viewed a video of workers applying the coating to a brick wall, followed by a local graffiti artist spray painting a mural of the city onto the coated wall. Then, attendees were captivated and

impressed as they watched the large skyline painting being promptly washed off the wall using a standard pressure washer. The coating had been applied a week before the event, and the mural was painted three days prior to the demonstration and left to bake in the hot summer sun. The pressure washer removed the entire mural in minutes, revealing how easily graffiti can be removed from surfaces treated with the Anti-Graffiti Coating.

Guests were then invited to enjoy lunch and networking, followed by a Q&A session in the early afternoon – where city officials showed interest in the value of Sherwin-Williams Anti-Graffiti Coating.

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Sherwin-Williams Protective & Marine Coatings invited officials from the Ohio Department of Transportation, the City of Cleveland and the Greater Cleveland Regional Transit Authority to witness spray-painted graffiti be simply washed away using nothing more than a standard pressure washer. The demonstration was staged on August 13 at the company’s John G. Breen Technology Center to show officials the benefits of its Anti-Graffiti Coating.

The live power washing demonstration brought to life how the coating could help Cleveland protect and enhance aesthetics citywide.

FOOD PLANT FLOORING

Anti-Graffiti Coating enables graffiti removal with ease to beautify cities

STI AWARD

ANTI-GRAFFITI COATING TO CLEVELAND CITY OFFICIALS

CORNELIA MARIE

SHERWIN-WILLIAMS SHOWCASES

CONTENTS

FEATURE

IMPACT AWARD ANTI-GRAFFITI COATING 2016 NEW PRODUCTS

“The coating offers the potential to help reduce graffiti cleanup and removal costs for municipalities nationwide.”

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Sherwin-Williams offers a variety of anti-graffiti solutions for both interior and exterior use. The special coatings protect commercial and municipal buildings and infrastructure, schools, bridge abutments, transit stations, overpasses, fences, rail cars, commissioned artwork and new construction from unsolicited graffiti through quick, economical removal.

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According to Keep America Beautiful (KAB), municipalities with graffiti problems can experience decreased feelings of safety among citizens and visitors, lower retail sales, reduced ridership on transit systems, and lower property values. Therefore, cities spend millions of dollars annually on graffiti cleanup to enhance the beauty and general welfare of their communities. These efforts can especially pay off when graffiti removal can be done quickly and efficiently, as KAB reports that repeat defacing is reduced – almost to the point of complete elimination – when graffiti is removed from a municipal surface within the first 48 hours.

STI AWARD

Sherwin-Williams’ Anti-Graffiti Coating is a costeffective, ready-to-use solution intended for use over bare concrete or previously painted surfaces. It offers excellent graffiti resistance and ease of cleaning, without leaving any shadowing or staining. Anti-Graffiti Coating is a permanent solution that creates a nonstick surface to repel graffiti from paint, paint spray cans and permanent markers without chemical cleaning, abrasives, repainting or reapplication. The product is long lasting and easy to apply via brushing, rolling, or spraying.

CORNELIA MARIE

Anti-Graffiti Coating is a permanent solution that creates a nonstick surface to repel graffiti from paint, paint spray cans and permanent markers without chemical cleaning, abrasives, repainting or reapplication.

ANTI-GRAFFITI COATING

FOR WATER AND WASTE WATER FACILITIES

IMPACT AWARD

WATER & WASTEWATER APP

CONTENTS

e coatingsolutions

2016 NEW PRODUCTS CORNELIA MARIE STI AWARD

Asia

The recommended/primary coatings and primers

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Process descriptions, areas of application and recommended applications

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Expert coating recommendations available at your fingertips

Alternative coating systems

Coating attributes

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DFT (mils) for each coat and total dry mils

Available for iOS and Android

Learn More www.sherwin-williams.com/protective

© 2016 The Sherwin-Williams Company

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VIEW FROM CONCRETE BRIDGE

North America 1.800.524.5979

CONTENTS

IMPACT AWARD

2016 NEW PRODUCTS CORNELIA MARIE

STI AWARD

FOOD PLANT FLOORING

®

DURA-PLATE 2300

®

VIEW FROM CONCRETE BRIDGE

HEAT-FLEX 3500

EVENTS

DURA-PLATE 6100

®

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BRIDGE & HIGHWAY VETERAN

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ANTI-GRAFFITI COATING

2016 NEW PRODUCTS

CONTENTS

NEW PRODUCT

IMPACT AWARD VIEW FROM CONCRETE BRIDGE BRIDGE & HIGHWAY VETERAN

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Dura-Plate 2300 is suited for resurfacing concrete prior to coating and lining applications for a wide range of environments, including water and wastewater facilities, the oil and gas industry, pharmaceutical facilities, bridge and highway, food and beverage sites, power generation facilities, mining, sewer collection, atmospheric and immersion service, and secondary containment.

EVENTS

Dura-Plate 2300 can be dry to touch in three to four hours and cures for immersion in 12 hours at 75° F.

The Sherwin-Williams Dura-Plate 2300 resurfacer has an excellent film build up to ½” thickness per lift and it can be top-coated in eight hours with nonflake-filled coatings and 24 hours with flake-filled coatings.

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With a wide range of application temperatures, the product allows for a longer season for application. Its unlimited recoat window accommodates any project demands, as it can be reagitated to reduce viscosity and improve workability time inside of its lengthy 70-minute pot life.

“With concrete being the most commonly used construction material in the world and knowing that concrete commonly experiences placement defects, Dura-Plate 2300 provides an easy and economical solution for resurfacing,” Morris said.

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“Dura-Plate 2300 is the perfect alternative to the high cost of epoxy resin fillers and the curing restrictions associated with cementitious resurfacers,” said Kevin Morris, Water and Wastewater Market Director, Sherwin-Williams Protective and Marine Coatings.

Available in flat concrete gray, Dura-Plate 2300 can be applied via hand trowel or spray at package consistency and it releases easily from the trowel to reduce worker fatigue. The addition of potable water can aid in spray application characteristics.

STI AWARD

The abrasion-resistant coating is part of a complete three-component kit from Sherwin-Williams that contains Portland cement, hydrophobic thixotropes, fiber reinforcement, graded silica sand and other aggregates. It contains the Part A Epoxy, Part B Hardener, and Part C Mortar in a single packaged solution that makes ordering simple, while saving time with processing and application on the job.

The product can be applied at a minimum of 40° F. Without the need for heated cure in colder temperatures and moist curing in hot environments, Dura-Plate 2300 prevents the application and curing restrictions associated with cementitious repair mortars.

CORNELIA MARIE

Sherwin-Williams Protective and Marine Coatings announces the launch of Dura-Plate® 2300, an epoxy-modified cementitious resurfacer for patching and filling voids and bugholes in concrete and masonry structures. Dura-Plate 2300 provides a hard, durable surface with excellent adhesion that minimizes the potential for pin-holing and outgassing problems typically associated with coating concrete.

2016 NEW PRODUCTS

Dura-Plate® 2300 provides cost-effective, three-component kit for cementitious resurfacing

ANTI-GRAFFITI COATING

WATER-BASED SOLUTION FOR CONCRETE AND MASONRY RESURFACING IN INDUSTRIAL, COMMERCIAL, AND ARCHITECTURAL APPLICATIONS

CONTENTS

NEW PRODUCT

IMPACT AWARD ANTI-GRAFFITI COATING VIEW FROM CONCRETE BRIDGE BRIDGE & HIGHWAY VETERAN

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Dura-Plate 6100 provides a high-strength lining for severe wastewater and sewer collection structures and is designed for manholes, basins, wet wells, clarifiers, lift stations, influent channels, trenches, pipes, sumps, and digesters. It is suitable for power generation facilities, mining, food and beverage facilities, the pulp and paper industry, secondary containment, and industrial wastewater treatment.

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Dura-Plate 6100 is an ultra-low VOC, spray-applied, resinous coating capable of film builds of 125+ mils in a single coat. With multiple passes of the gun, the product will provide the end user with structural

Available in off-white, the coating increases visibility and offers improved light reflectance value, allowing for inspection without entry. Its excellent chemical resistance supports life cycle improvement, and because it contains no solvent, spark hazards in confined spaces are eliminated.

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“This product offers the greatest physical strengths of any epoxy in our line today,” said Kevin Morris, Water and Wastewater Market Director, Sherwin-Williams Protective & Marine Coatings. “It is the premium product in the Dura-Plate family of linings.”

“Dura-Plate 6100 shall be the product of choice for the proven solution-seeking customer because of its competitive performance results, fast dry and returnto-service times, as well as Sherwin-Williams’ application support for severe wastewater service,” said Morris.

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The new product is designed for time and cost savings as it offers quick dry-to-touch times that reduce the potential for outgassing on buried concrete structures and rapid return-to-service times of 12 hours to prevent downtime and increase productivity. At 77°F, the coating is dry to touch in only 30 minutes and it cures for immersion in 12 hours. It can be applied in temperatures as low as 50°F.

enhancement of the host substrate through semistructural properties and lower permeability. It reduces the potential for pinhole formation due to the rapid dry-to-touch times.

STI AWARD

Sherwin-Williams Protective & Marine Coatings launched Dura-Plate® 6100, a 100% solids high build, high physical performance, amine-cured epoxy designed for corrosion protection of concrete and steel in municipal and industrial wastewater treatment facilities. The product helps to extend the design life of a coated structure.

CORNELIA MARIE

Dura-Plate® 6100 designed for high build and high physical value requirements

2016 NEW PRODUCTS

PREMIUM CORROSION PROTECTION SEMI-STRUCTURAL EPOXY FOR WATER AND WASTEWATER MARKET

CONTENTS

NEW PRODUCT

IMPACT AWARD BRIDGE & HIGHWAY VETERAN

Heat-Flex 3500 is suited for a wide range of environments, including oil and gas refineries, chemical, power, water, wastewater, and food and beverage plants, pulp and paper mills, and marine and offshore structures.

VIEW FROM CONCRETE BRIDGE

“We now have a full spectrum of coating and lining offerings, ensuring consistent availability and optimal performance for our customers,” Knecht said. “This gives us an even greater ability to think holistically across the plant MRO environment so our customers can achieve the results they’re after in the most costeffective way.”

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With the addition of Heat-Flex 3500, Sherwin-Williams now offers plant owners and operators a single source for insulative coating systems, including primers and topcoats.

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“Every plant is concerned with safety and minimizing CUI risk,” said Ron Knecht, Regional Market Director, Oil and Gas, Sherwin-Williams Protective & Marine Coatings.

“Heat-Flex 3500 offers industrial operations a new way to protect their most valuable assets – their personnel – from injuries. In addition, the coating system can

Heat-Flex 3500 goes on fast and easy to save application time and costs. Its single-component, waterborne acrylic formulation can be applied with standard airless equipment. Its very fast dry time allows for recoating within two hours. In addition, Heat-Flex 3500 minimizes overspray risks with droplets drying to a non-adhering dust within a 20-foot fall.

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The insulative and anti-corrosive properties of Heat-Flex 3500 enable plant owners to eliminate concerns related to CUI. The protective coating system prevents corrosion-causing condensation on the exterior of piping, ductwork, and other surfaces wrapped in conventional insulation and cladding. It performs so well at mitigating corrosion that structures coated with Heat-Flex 3500 can be removed from CUI inspection protocols.

Available in white and slate gray, Heat-Flex 3500 is ideal for coating everything from pipes, valves, tanks, vessels, heaters, and boilers to compressors, pumps, containers, stacks, and ductwork that operate in temperature ranges between -80° F and +350° F.

STI AWARD

Heat-Flex® 3500 is a multipurpose insulative acrylic coating for industrial systems that’s designed for both personnel protection and mitigating CUI. The coating enables dangerously hot systems like piping and ductwork to stay cool to the touch, preventing burns and protecting the safety of personnel. It can be applied directly to ambient or hot surfaces up to 350° F (177° C), offering plants the flexibility to reduce downtime by keeping systems online during coating and recoating applications. In addition, Heat-Flex 3500 also insulates hot and cold surfaces, helping industrial processes retain heat and preventing condensation on cold surfaces by maintaining surface temperatures above the dew point.

eliminate CUI, one of the costliest problems facing processing environments today.”

CORNELIA MARIE

Industrial businesses looking to enhance worker safety and minimize corrosion under insulation (CUI) risks can turn to a new insulative acrylic coating from Sherwin-Williams Protective & Marine Coatings.

2016 NEW PRODUCTS

Heat-Flex® 3500 prevents burns and can be applied directly to surfaces up to 350° F

ANTI-GRAFFITI COATING

NEW THERMAL INSULATIVE COATING MINIMIZES CUI RISK AND OFFERS PERSONNEL PROTECTION

IMPACT AWARD

ANTI-GRAFFITI COATING

2016 NEW PRODUCTS CORNELIA MARIE

STI AWARD

FOOD PLANT FLOORING

VIEW FROM CONCRETE BRIDGE

BRIDGE & HIGHWAY VETERAN

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EVENTS

A CATCH WITH CORNELIA MARIE CREW

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SHERWIN-WILLIAMS PROTECTIVE & MARINE

CONTENTS

CASE STUDY

CONTENTS

CASE STUDY

IMPACT AWARD ANTI-GRAFFITI COATING 2016 NEW PRODUCTS

Alaska Renovations:

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BRIDGE & HIGHWAY VETERAN

With no store in Kodiak, Alaska, Meador wrote a specification and put together a schedule to ship the desired products to the Kodiak shipyard from Seattle,

Surface preparation consisted of removal of loose debris with hand and power tools, priming with Corothane® I Mio Aluminum where UHS had exposed bare steel, and edge feathering above the waterline to ensure the 1.5 mil profile necessary for proper adherence.

VIEW FROM CONCRETE BRIDGE

Protective & Marine sales representative Ray Meador was pleasantly surprised when he took the call from McManus, who had a very strong preference for Sherwin-Williams products.

While this was going on, other details were set in motion under the watchful eyes of technical services representative Sam Schuetz, who was on site for preparation and application of coatings. This included bringing coating applicator C&M Enterprises up to speed on all aspects of the specified coating system to be spray applied. With a thorough review of the product data pages, they understood what products went where and the characteristics of each.

EVENTS

The Cornelia Marie is a 128-foot all steel twin-screw vessel. Built in 1989, it had been five years since its last recoat. It was high time to mitigate the effects of working in the Bering Sea crab business with its harsh elements and heavy impacts from fishing pots.

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Job one for the crew was washing down the underwater hull, which took the better part of four days under the oversight of Paradigm Marine. This was a multi-step process, starting with a light pressure wash to remove growth and slime. As the steel was largely in good condition, the team determined that the hull could be taken down to the existing tight anti-fouling coat using an ultrahigh pressure wash at 38,000 psi.

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For new owner Josh Harris, co-Captain Casey McManus, their deckhands, and Sherwin-Williams, that meant a hectic ten days of dry dock coating work on the underwater hull and freeboard in Alaska to prepare the Kodiak-home port vessel for its triumphant return.

Sherwin-Williams would then complete additional restoration work on the ship’s main deck and engine room mid 2015 in Seattle, Washington.

STI AWARD

Washington within a week. The makeover called for a coating system that could deliver strong aesthetics to a high profile vessel, but also offer durability and anti-fouling long-term protection, was low temperature-resistant, and could be partially applied by deckhands.

CORNELIA MARIE

If a documentary-style TV show makes it to a tenth year in today’s crowded entertainment universe, there is cause for celebration. So when the top-rated show, Deadliest Catch, unveiled its plans for the 2015 season, a revisit with the popular crabbing vessel F/V Cornelia Marie was high on the agenda.

“Casey and Josh are great to work with,” Schuetz concluded.

With fresh coatings and supplementary restorations, Cornelia Marie was transformed and ready for prime time once again.

CORNELIA MARIE STI AWARD

Once the lettering and cap rail was trimmed out and the crew did preparation of bulwarks, the Cornelia Marie was ready to set sail again on Alaska’s high seas.

With some strategic planning, careful coordination, and good communication with the famous owners and crew to complete all of the remodeling at once, Sherwin-Williams succeeded in providing a quality product to help enhance the famous ship.

2016 NEW PRODUCTS

The next day, Schuetz worked with C&M and the crew to catalyze the High-Solids Polyurethane Gloss in the distinctive Cornelia Marie teal that Sherwin-Williams matched from a paint chip. This acrylic polyurethane applied WFT 4-8 mils provides the steel substrate with superior adhesion and impact resistance, even with repeated impacts from fish pots that would shatter other coatings, while still delivering outstanding color and gloss retention.

“The interior of the Cornelia Marie was getting a new galley and living quarters,” said Schuetz. “Working the painting schedule around all of the other remodel projects was challenging, especially since the engine room needed to be painted before the new engines could be installed.”

ANTI-GRAFFITI COATING

The first weekend was busy. Spray application of a tie coat of SeaGuard® 6000 primer to the hull was followed – within hours to avoid delamination – by a single coat of SeaGuard Ablative AF epoxy to a wet film thickness of 10-12 mils. Single-component SeaGuard maintains effective, bioactive protection during its entire life.

new engines and an updated living area. This would present an extra challenge to the applicators.

IMPACT AWARD

Once a travel lift moved the Cornelia Marie to the pad, the crew put up reinforced polyurethane plastic to meet containment regulations and masked the areas of the freeboard that had lettering and other design elements.

CONTENTS

CASE STUDY

Washington Renovations:

BRIDGE & HIGHWAY VETERAN

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VIEW FROM CONCRETE BRIDGE

Along with the coatings applications, the famous vessel was also receiving other updates, including

EVENTS

As for updates to the ship’s engine room, Sherwin-Williams supplied the owners with additional SeaGuard 6000, along with Hi-Solids Polyurethane. The engine room coatings required spray application at the Northlake Shipyard in Washington. The SeaGuard 6000 was applied to a wet film thickness of 5-7 mils, while the Hi-Solids Polyurethane was applied at 3-5 mils DFT per coat.

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Due to time constraints, equipment could not be brought in to blast the deck and apply zinc for the second set of renovations on the boat, so the owners decided to again utilize SeaGuard 6000 epoxy on the main deck. The three coats were applied by brush and roller by the Cornelia Marie crew at 5-7 mils DFT per coat.

FOOD PLANT FLOORING

A few months later, the Cornelia Marie was ready for some more primping in order to revamp the main deck and lower house and to repower the vessel’s engine room. For these applications, the ship was stationed in Seattle, Washington in the Spring.

CONTENTS

e coatingsolutions

IMPACT AWARD ANTI-GRAFFITI COATING CORNELIA MARIE

WEFTEC CONFERENCE 09.24-28 NEW ORLEANS

2016 NEW PRODUCTS

SHERWIN-WILLIAMS IMPACT AWARD

STI AWARD

MAY 1 THROUGH JULY 31, 2016 www.sherwin-williams.com/impactaward

Although you avoid the spotlight, Sherwin-Williams Protective & Marine wants to shine just a little light on the professionals who maintain our water and wastewater infrastructure – introducing the Sherwin-Williams Impact Award.

Entries will be reviewed by an independent panel of water industry experts. A presentation of the three finalists will be made at an award ceremony at WEFTEC New Orleans on September 27.

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BRIDGE & HIGHWAY VETERAN

© 2016 The Sherwin-Williams Company

VIEW FROM CONCRETE BRIDGE

Application contractors, the specifiers and owners of North American water and wastewater projects are encouraged to enter. Details are available online at www.sherwin-williams.com/impactaward.

EVENTS

The Award is open to any water-related structure that is new, restored, and/or rehabilitated, and has been completed with Sherwin-Williams Protective & Marine coating and lining material from January 1 through December 31, 2015.

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The work you do often occurs behind the scenes but its impact is immeasurable: protecting our most valuable resource, safeguarding our families.

FOOD PLANT FLOORING

CALL FOR ENTRIES:

CONTENTS IMPACT AWARD ANTI-GRAFFITI COATING VIEW FROM CONCRETE BRIDGE BRIDGE & HIGHWAY VETERAN

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The Annual Product of the Year award is presented by STI to recognize new products, services, or supplies of affiliate member companies that enhance the fabrication, versatility, and longevity of steel tanks and pressure vessels. Sherwin-Williams has previously received this award for Dura-Plate® UHS with OAP, Dura-Plate® 301, and Nova-Plate® 325.

EVENTS

EnviroLastic® 940 DTM is a high build, direct-to-metal coating that can also be applied at temperatures as low as 35°F. The advanced chemistry of this polyaspartic urethane produces accelerated throughput by offering one-hour dry-to-touch times, while the high build property provides single-coat application with the performance of most two-coat epoxy/urethane systems.

“Our products perfectly address the challenges facing STI Shop Fabricated members,” added SherwinWilliams Protective & Marine Coatings Project Development Manager Tony Ippoliti, who has served on the Board of Directors, as an Affiliate Member Chair, and as the Sherwin-Williams liaison with the Steel Tank Institute since 2000. “The Steel Tank Institute is different from other associations in that it is comprised of and attended by the owners of the steel tank, pipe, and pressure vessel companies and their suppliers.”

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EnviroLastic® 840 DTM is a high gloss, thin film, directto-metal coating that is early-moisture resistant and can be applied in temperatures as low as 35°F. The short 20-minute dry-to-touch window greatly reduces grit pickup, and it finishes with a mirror-like appearance.

“We are honored to receive this prestigious award for our EnviroLastic product line,” said Danica Zeise, Product Manager, Sherwin-Williams Protective & Marine Coatings. “Our EnviroLastic products offer fast turnaround and are ideal for applicators in the petroleum, chemical, agricultural, and water infrastructure industries.”

FOOD PLANT FLOORING

The foundation of the EnviroLastic Polyaspartic product line is high-throughput applications for shops.

These products were also designed to provide performance, durability, and ease of workability for applicators. Specifying these new technology coatings can provide improved levels of efficiency, allowing accelerated throughput not previously imaginable and at significantly lower overall cost, as they were engineered to provide long-term performance and aesthetics.

EnviroLastic® 980 PA is a premium high build finish coat designed for long-term durability. This next generation polyaspartic urethane technology provides the ability to turn around a maintenance coating application in just one shift and offers an extended recoat window of three months.

STI AWARD

Earlier this year, Sherwin-Williams Protective & Marine Coatings was awarded the Steel Tank Institute (STI) 2015 Affiliate New Product of the Year for its EnviroLastic® Polyaspartic coatings at STI’s annual meeting in partnership with the Steel Plate Fabricators Association.

CORNELIA MARIE

Polyaspartic Technology Provides Adhesion and Corrosion Resistance, Color and Gloss Retention

2016 NEW PRODUCTS

SHERWIN-WILLIAMS AWARDED THE STEEL TANK INSTITUTE’S 2015 AFFILIATE NEW PRODUCT OF THE YEAR AWARD FOR NEW ENVIROLASTIC ® POLYASPARTIC URETHANES

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FOOD PLANT FLOORING The text from this article was originally published in the February 2015 issue of Food Engineering, a BNP Media publication. It has been reprinted with their permission.

For those involved in deciding on a plant floor, the process might resemble the children’s story of “Goldilocks and the Three Bears.” One flooring option might be too odorous, another might crack too easily, and another costs too much. Adding to the difficulty of the decision is the varying nature of food and beverage processing environments—what is appropriate for one type of application may be completely inappropriate for another.

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“Epoxies are multilayered systems, so they require many steps and might not cure as fast,” Kwasny says, “and they end up cracking over time.”

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“Epoxies are a good choice for an aesthetically pleasing and durable floor when the temperature range is above 55°F, vapor emissions from the concrete are below three pounds, or a moisture control system is installed,” states Adelmann. However, epoxies do have some mixed results regarding their durability.

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Another type of coating is epoxy, which remains a popular resin flooring option due to its lower cost and fast drying times. FDA and USDA have approved a number of epoxy flooring systems, including those with a 100 percent solids binder resin with a blended aggregate, for food and beverage processing facilities.

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“Epoxies, urethanes and MMAs are all useful for [food and beverage] applications,” says Chris Smedley with High Performance Systems in Middlesex, NJ. Resinous flooring has many advantages over other offerings like vinyl composition tile (VCT) or quarry tile floors. “For one, resinous floors can accomplish a wall-to-wall, seamless surface, which eliminates hiding

MMA cures chemically as opposed to air drying, which also explains why it can be applied in areas that reach down to -20°F, making it a good candidate for cold rooms or freezer storage areas. However, since MMA curing is very fast, it is strongly recommended that a highly experienced contractor with a good team do the installation.

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Therefore, the coating must be durable enough and thick enough to form a barrier to ensure a sanitary environment. For instance, the flooring in food and beverage processing plants may need to withstand a wide variety of substances, including the oil present in a plant that produces, for instance, snack foods or the sugar present in an industrial bakery. Flooring also must stand up to vacillating temperatures and exposure to aggressive cleaning solutions. There are three basic types of protective resin coatings to consider for concrete flooring: methyl methacrylate (MMA), epoxies and urethanes.

“They are extremely odorous,” says Keith Kwasny, president of SaniCrete in Farmington Hills, MI, “so they should be used only in well-ventilated areas. That’s the downside to the speed.”

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First and foremost, food and beverage plants must protect any concrete flooring in the processing area for hygienic reasons. “Concrete is basically a sponge,” explains Sean Walsh, marketing manager of Protective Industrial Polymers in Berea, OH. “If water penetrates the concrete, it’s very dark, it’s very damp, and you can’t get cleaners down there. That’s the perfect environment for microbial growth.”

One of these coating options is MMA, also referred to as acrylic flooring. “The benefit of this type of flooring is its quick turnaround to service,” says Baron Adelmann, president of Techniquex in Scottsdale, AZ. “These products dry and can be cured in as little as 30 minutes. The downside to them is that they have poor UV resistance and a very strong odor during installation.”

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Considering the options

places for bacteria and allows the floor to be more thoroughly cleaned and sanitized. The polymers used to create resinous floors are also quite a bit stronger and more durable than the alternatives.”

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Nevertheless, the type of flooring chosen is one of the most important decisions to be made because not only will it be used every day, it is costly to install, both in terms of materials and lost productivity if a shutdown is required. Moreover, with an increased emphasis on sanitation, today’s plant floor has to withstand much harsher cleaning practices and undergo more scrutiny than in the past, adding to the importance of its reliability and durability.

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Flooring must withstand an enormous amount of abuse, so whatever material is chosen, it needs to last, be safe and stay clean.

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RELIABLE AND DURABLE PERFORMANCE FROM THE BOTTOM UP

The only drawback with cement urethane floors is cost.

“You’re going to pay a little more,” says Kwasny.

“A lot of the longevity question depends on the final use of the area and recommending the right system for it,” adds Walsh.

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Next, a finish needs to be determined. “All the options can be produced in various textures, including non-slip and high-gloss finishes,” says Smedley. This is important since non-slip coatings are required in many processing environments to increase worker safety.

Aggregates added to the coating can change the texture and hardness of the floor.

SlipNOT stainless steel flooring has a coefficient of friction, or resistance to slip accidents, greater than 0.85 compared to the US Occupational Safety and Health Administration’s recommended score of 0.50 or above for workplace environments. Schroeder says the floors “are extremely durable and long lasting, registered by NSF International, and chemical and corrosion resistant.

Plus, they can withstand the extreme heat of cookers or extreme cold of cryogenics.”

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1. The typical contaminants introduced to the floor (i.e., the chemicals, cleansers or oils that might touch the floor’s surface).

“When using an epoxy, a solid color floor is recommended,” says Adelmann. “Clear epoxies do not have good UV stability. Even UV-resistant epoxy will amber and yellow over time. It just does it more slowly than standard epoxies.”

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Smedley says High Performance Systems’ flooring engineers observe the space and its typical workflow to determine the best material for it. They consider the following five major pieces of information:

The next thing to consider is the appearance of the floor, whether it needs to be glossy or more matte.

This can be a decorative matter, but in some instances, the choice can contribute to the durability of the floor.

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“There are different types, different thicknesses and different textures [of flooring]. The key is understanding the environment,” Kwasny says. “If you spend time in the beginning to pick the right floor, you’re going to minimize your headaches going forward.”

Considering the temperatures the floor will be exposed to is equally important. “In high-temperature situations, we always use cement urethanes or MMAs, as tempting as lower-cost epoxy options may be,” explains Smedley. “Bakeries often see floor failure underneath hot lines or ovens when a low-cost epoxy has been installed.”

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All the flooring providers, no matter their offerings, agree on one thing: You must understand your plant’s environment and needs.

“If you select a thin floor, for instance, one-eighth or one-quarter inch, and you have an abusive environment that will damage the coating, you’ll have a spot collecting bacteria that you’ll have to patch,” says Kwasny. The repairs will cost a lot more to fix than if an appropriate match was made in the beginning.

FOOD PLANT FLOORING

Making the right choice

An assessment informs flooring engineers of how thick the coating needs to be, with thicker floors having greater shock value and a longer wear cycle.

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As for non-resin flooring, one solution is offered by Detroit, MI-based SlipNOT, which manufactures slipresistant stainless steel flooring products, such as floor plates, grating, stair treads, drain covers, floor scale tops and ladder rungs. “SlipNOT products are installed for a wide variety of food and beverage applications, specifically where oils, fats and other liquids are prevalent,” says Grace Schroeder, marketing manager for SlipNOT.

5. Timeframe allotted to produce a floor with minimal downtime for the facility.

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“In environments that do a lot of hot and cold water washdowns, people tend to go with a urethane concrete because that system has a similar rate of expansion to concrete. It expands and contracts in unison with the concrete, which makes it less susceptible to cracks,” says Walsh.

4. Budget available to complete the project.

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According to Kwasny, cement urethane floors are nonodorous and cure fast. In fact, Kwasny recommends this flooring over the others.

3. Workplace safety issues including the need for non-slip coatings, line striping, etc.

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Cement urethane has a thermal coefficient of expansion that is almost identical to concrete, says Adelmann. “Therefore, hot water washdowns do not affect them the way they do other floor goods.”

2. Mechanical challenges imposed upon the floor (e.g., heavy forklift traffic, strong impacts from machinery, frequent thermal shock from cooking apparatuses, steam cleaning or refrigeration).

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One flooring option growing in popularity is cement urethane, which was designed for use in food and beverage processing applications. “More and more facilities are moving toward cement urethane,” says Smedley. “Its incredible strength, resistance to temperature fluctuation and long lifespan make it hard not to use.”

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FOOD PLANT FLOORING

Antimicrobial choices and sanitary design

Flowcrete Americas combines natural silver ion-based antimicrobial into the matrix of its resin flooring material.

“In an exclusive global partnership with Polygiene,

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“Antimicrobial additives can also be dispersed in the resins, providing further protection from bacteria, if the topcoat should be scratched,” says Smedley.

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Proper installation is crucial to the performance and lifespan of the floor. “Most floor failures are created by bad preparation of the substrate. The only way to remedy these failures is to hire a knowledgeable contractor from the beginning,” Smedley says. “All

“Stainless steel products will not contaminate the end product and are resilient to cleaning agents,” says SlipNOT’s Schroeder. However, resinous floors are often promoted as a more hygienic solution because they are seamless, thus making them easier to clean and reducing the number of areas where bacteria could thrive.

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“A good floor contractor can minimize downtime by using quick-curing products or staging the project in multiple mobilizations, shutting down only a small section of the facility before moving on to the next,” observes Smedley. “The best-case scenario is our team coming in on an off-production night, installing everything, returning all the equipment to its normal placement and leaving no downtime for the facility.”

regulations recommend processing plants use materials that are impervious to water and can withstand the use of more aggressive cleaning chemicals and routines.

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“A lot of processors either can’t or don’t want to change their environments. For instance, they may have a 38°F cooler,” he says. When this is the case, a competent flooring engineer can help a processor find solutions that do not need higher installation temperatures.

FOOD PLANT FLOORING

“We’ve been shortening the cure times, shortening the install times—without, of course, impacting the quality— and bringing the product to cure at cooler temperatures,” “The FSMA includes the most sweeping food safety he says. “In the past, 48 hours was pretty typical to laws in the past 70 years,” says Rebecca Dolton, install, but now it’s closer to 30 to 36 hours because the regional market segment director of food and processors are not giving us more time.” beverage for Sherwin-Williams Protective & Marine Coatings. “Facilities are under tough scrutiny by thirdEven in the new plants, Kwasny says, flooring party auditors to maintain a clean, safe working companies are being given less and less time since environment.” they are on the back end of construction, and if projects take longer up front, builders try to make the USDA and FDA guidelines state that food time up later. Additionally, installing floors at cooler contamination risks can be reduced by installing a temperatures has become a major sticking point in flooring product with the best food safety standards some jobs. built into its design. To ensure a sanitary floor, the

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More stringent sanitation regulations for food and beverage processing environments, spurred by the pending Food and Safety Modernization Act (FSMA), are drawing new attention to the cleanability of flooring.

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Faster installation and drying times are becoming critical issues for food and beverage processors that want less downtime during construction or renovations. Kwasny says his company has been working on three things in the last few years to meet the needs of his clients.

“The more profile you have, the better bond you have and the less risk of floor failure,” he says. Protective Industrial Polymers actually pretreats the concrete slab with a product that forms an aqueous, antimicrobial gel. “One of the biggest causes of failure is undercutting, where chemicals or water works its way underneath the coating and causes it to fail.

Pretreating the concrete takes away the absorption, so the chemicals are less likely to undercut the coating.”

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Installation

Pat Scudder, president of Protective Industrial Polymers, recommends installers do more profiling, or blasting off the top of the concrete, to make the surface rough enough for the toppings to mechanically bond to the substrate.

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“This floor is tough, it stands up to everything we dish out, and aesthetically, it’s beautiful,” says Coca-Cola Facilities Manager John Chubbuck.

flooring projects should begin with slab remediation— addressing control joints, expansion joints, settling of the slab, cracking, removal of old sealants, abrading the surface to achieve a good bond, etc.”

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All this information goes into determining the right flooring for the environment. For example, Techniquex was contacted to install a floor at the Coca-Cola bottling facility in Tempe, AZ. Since the area has high forklift traffic along with hot water washdowns, the flooring needed to be resistant to thermal shock, impacts and abrasion, as well as easy to clean. Also, Coca-Cola wanted the final product to look good. A 48-hour installation window was given, so Techniquex specified DIAMONDSTONE food process flooring RT, finished with a quartz aggregate broadcast with a clear topcoat of polyaspartic urethane.

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FOOD PLANT FLOORING

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FOOD PLANT FLOORING

February 2015 | www.foodengineeringmag.com

ALSO THIS MONTH } ROBOTIC GRIPPER WITH A LIGHT TOUCH } SPECIAL SUPPLEMENT ON FLOORS } FOCUS ON DRY PROCESSING TECHNOLOGY

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Stop energy leaks with the right tools

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When a plant does experience that eventual floor failure, Scudder says the pretreatment of the concrete will still provide antimicrobial support and help with repairing the coating. “That pretreatment helps keep the concrete from absorbing chemicals and contamination, so it’s as simple as re-profiling the concrete and reapplying the coating. You don’t have to extract any contamination or try to sterilize the concrete.”

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However, questions surrounding a flooring’s durability and length of service always remain, and inevitably, the coating will wear out or fail in some way. “No matter how the polymers are put in, they are, by definition, a temporary solution,” says Protective Industrial Polymers’ Scudder. “The only permanent function is the substrate itself, so it seems crazy not to make that antimicrobial because then you have permanently improved antimicrobial protection.”

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EXCLUSIVE REPORT: TIPS AND TECHNIQUES TO AVOID LABELING-RELATED RECALLS

FOOD PLANT FLOORING

“The whole idea is redundant antimicrobial protection, which fits in very well with FSMA,” he continues.

“That’s our whole kind of world—creating a building envelope protection, where you can coat the walls and the floors and integrally connect them, so it’s a very sanitary environment without breaks or voids.”

“It ties directly into the wall system, providing a seamless transition from floor to wall,” says Dolton.

“This eliminates the opportunity for bacteria to collect in the area where the floor meets the wall and allows for better cleaning. When a cove base is installed with a proper slope to drain, ponding water is reduced.”

And this can help prevent the flooring from becoming an issue in the facility’s next audit.

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“We pretreat the concrete [in InhibiCrobe floor and wall systems] before putting any antimicrobial top coating on it,” Walsh says. A colloidal product is sprayed onto the concrete, penetrating six inches deep, filling all of the voids and forming an aqueous gel to densify the substrate with antimicrobial properties.

New regulations dictate plant flooring should be easy to clean, even in corners where the floor meets the wall, which, because of their inaccessibility, are identified as places of potential bacterial growth. To remedy this situation, FDA suggests “there must be coving at base junctures that is compatible with both wall and floor coverings. The coving should provide at least a one-quarter-inch radius and four-inch height.”

Most flooring companies now offer this type of cove base application, such as Sherwin-Williams’ FasTop urethane concrete flooring system.

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because puddling water is a no-no in the food industry.”

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“What we found out is that it could be or it couldn’t be [antimicrobial],” he says. By working with an independent test lab, Protective Industrial Polymers discovered additives react differently when mixed with various materials. According to Walsh, “A certain percentage of an antimicrobial additive in an epoxy might work, but if you mix it into urethane, it may not react in the same way,” which might make it less effective. The company decided the antimicrobial product needed to be manufactured at its plant rather than mixed in the field.

“The ideal situation eliminates all standing water and However, there has been some debate surrounding debris from the floor as quickly as possible,” offers the effectiveness of these antimicrobial flooring options. Smedley. “To this end, trench drain placement, sloping “Antimicrobial additives are not new; they’ve been the slab toward drainage and top coating [the floor] around for a while,” says Walsh of Protective Industrial with an impervious and seamless system are Polymers. “Many companies utilize them, and in the paramount.” past, we were one of them.” He explains that if a crew “As for sloping the drains, that’s absolutely crucial in a mixes the coating material in the field with an retrofit,” Kwasny says. “We can take a flat floor and antimicrobial additive before applying it, they can call slope it to that drain. At a minimum, one-eighth of an the flooring antimicrobial. inch per foot fall is important to get positive drainage

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The structural design of the flooring, specifically the physical orientation of it and how it drains, also has become crucial to the sanitation of a plant.

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Flowcrete has designed a cementitious urethane flooring system to reduce the bacterial population on the surface of the floor by up to 99.9 percent,” says Itzel Hernandez, marketing associate for Flowcrete.

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CONTRACTOR PROFILE

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CONTRACTOR PROFILE: M J Painting Contractor Corp.

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“Morning meetings to review safety and procedures were key to the project,” said the owner. “We followed strict guidelines for safety, such as LEAD procedure program, air quality monitoring, and ensuring employees working at heights had proper PPE requirements.”

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Despite their Northeastern location, M J Painting Contractor Corp. is ready and willing to send their talented crews to any location to complete a job.

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TOP JOB honors a single painting or wallcovering company in a city for superior work and commitment to excellence.

Their award-winning job at the refinery in Montana specifically posed a wide range of hazards, all of which M J Painting Contractor Corp. avoided through careful safety practices. With surface temperatures reaching 400 degrees and outdoor temperatures in the 90s, there was a risk of workers being burned, dehydration, lead paint issues, and falls for employees working on the project. In order to avoid these personnel safety issues, the team at M J Painting held daily meetings to evaluate protocol and keep safety in the forefront of everyone’s minds.

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“This is a very prestigious award that reflects our ability to manage and perform what has been voted Best Jobs in the Nation for 2014,” said owner, Mike John. “I feel honored. This was a proud accomplishment of our team.”

Setting Standards in Safety

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When they were contracted to coat one of the largest refineries in the Northwest, the New York-based company was nearly 2,000 miles from home. But the distance did not stop M J Painting Contractor Corp. from providing superior service and quality to the Laurel, Montana refinery. The job, which kept employees working 10-hour days, seven days a week for five weeks straight, was completed with no safety incidents on the crude oil heater.

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In 2014, M J Painting Contractor saw a record number of bids with more than 300. According to Mr. John, the company hired 11 new employees, increased their fleet of vehicles, and had several capital purchases helping their sales “hit an all-time high and profitability was solid.”

Winning Awards and Breaking Records The company also recently expanded their headquarters This year, M J Painting Contractor Corp. was honored in Olean, New York to include an office addition and a as a recipient of the American Painting Contractor (APC) warehouse with plans for additional land development 2015 TOP JOB Award, following record years for the and a new paint shop building to better service their company in 2014 and 2015. customers both locally and nationwide.

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“What is amazing to me is the fact that our customer demands have led M J Painting to work in multiple states,” said Mr. John. The company has serviced facilities as far as Montana and Kansas and has completed jobs in Indiana, Michigan, Ohio, Pennsylvania, North Carolina, South Carolina, West Virginia, Massachusetts, New Hampshire, Connecticut, Vermont, and Rhode Island.

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In 1970 when Mike John Sr. started a small house and local business painting company as a teenager in the Northeast, he hardly imagined the successful organization he was forming. Today, M J Painting Contractor Corp. is leading the way in service, safety, and quality within the commercial contractor painting profession. With 45 years in business and two recordbreaking years, their award-winning service is earning them distinguished recognition and business opportunities nationwide.

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“M J Painting Contractor Corp. has been a very valued client of The Sherwin-Williams Company for over forty years,” said Bruce Stutz, Coatings Representative. “M J Painting completes many of their projects using our highest, top-of-the-line Sherwin-Williams Protective and Marine Coatings. We have worked on and completed “My philosophy has always been to work hard, sacrifice, hundreds of coatings projects together and the result have integrity, perform quality work, and provide excellent has been many very satisfied and repeat clients.” customer service,” he said. “No organization is successful without a team effort.”

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Clients can attest that M J Painting is living up to their mission statement.

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Founded by Mr. John in his parents’ basement with only $200 worth of equipment, the company has grown significantly from its modest beginnings 45 years earlier. The family-owned business, still operated by Mike Sr., also features Mike John Jr. as the Vice President and Project Manager and Carol John as Operations Manager, along with a skilled staff of nearly 40 employees. According to Mr. John, hard work and high standards have helped to pave his way to success.

The mission of M J Painting is “To be the premier contractor of painting and coatings to the natural gas and oil, commercial, and industrial markets providing exceptional performance and outstanding customer service.” The statement continues, “Customer satisfaction and job safety is our pledge. We are committed to achieve the highest standards in the industry.”

FOOD PLANT FLOORING

A Legacy of Leadership

The owner concluded, “All of this is possible only with a good work force – and we have that! Our field personnel realize that quality, customer relations, and safety are a top priority.”

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M J Painting has an extensive health, safety, and environmental program that includes comprehensive training for employees, assuring the customer a safe work environment. With the assistance of ISNetworld, a global resource for connecting corporations with safe, reliable contractors in capital-intensive industries, M J Painting Contractor Corp. is maintaining high safety standards on their job sites. They also work with the Midwest Energy Association to provide operational excellence and to continually improve proficiency, efficiency, and safety.

“I am proud of the fact that we have developed a business where trust and integrity has played a big role in our success,” said Mike John Sr. “To be successful, we had to diversify our market participation to a national level – being a full turn-key painting contractor able to perform all aspects of painting, wall covering, sandblasting, epoxy coatings, tanks, towers, natural gas compressor stations, natural gas pipe lines, and oil refineries.”

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“Accolades to our safety administration, our field administration, and to our field personnel who face the everyday challenges of working safe along with getting the job done on time and on budget,” he concluded.

The company’s core values include reliability and honesty and they pride themselves on using quality products and providing top-of-the line services to their customers.

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“Safety is the number one concern with our employees and with our customers,” said Mike John, whose company has worked more than 1,500 days without a recordable safety injury as of August 31, 2015.

Today, M J Painting Contractor Corp. services commercial and industrial accounts, oil refineries, and the natural gas industry, among others. They are certified in sand blasting, epoxy coatings, plural component application, architectural painting, and more.

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The project involved abrasive blasting and application of Sherwin-Williams high-temperature Heat-Flex® 1200 coating on the active 400-degree crude oil heater steel surface.

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FOOD PLANT FLOORING

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e coatingsolutions

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A hallmark of the company’s philosophy is its integrated supply chain, set up to deliver quality, value and technical service and logistical support unmatched by any other coatings company.

From over 4,000 company-owned distribution points, Sherwin-Williams delivers.

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Sherwin-Williams is a single source coatings supplier with a comprehensive product line engineered to provide the highest corrosion protection with the fewest applied coats, thus improving the nation’s infrastructure at a greater rate. As a valued partner to bridge engineers, materials managers and painters, the company works to assure tight schedules are met and finished product expectations exceeded.

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© 2016 The Sherwin-Williams Company

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Beginning in 2009, NTPEP undertook to compile information that would identify the appropriate test methods for assessing concrete coating performance in atmospheric exposure and accelerated weathering. I am pleased to report that, as we close out 2013, we now have a consensus-based work plan for performance evaluation of concrete coatings that state transportation planners can use to develop their Qualified Product Lists.

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Applying coatings has long been viewed by bridge engineers as an installed maintenance burden — viewing coatings as a commodity that must be maintained frequently or replaced well prior to the end of the useful lifetime of the structure. But during the last five years, state bridge engineers have begun to ask for next-generation protective coatings with increased frequency. They are aware that the marketplace has made significant advances in coating technologies that allow highly durable materials to be engineered for specific applications and multifunctional performance properties. Coatings now provide both

Examples of modern coating materials specifically engineered to protect concrete structures include breathable waterborne epoxies that can be applied to green concrete, providing a protective film with excellent weathering properties while avoiding the traditional initial waiting period for the concrete to fully dry prior to coating application. Additionally, materials such as aliphatic polyureas and polyurethanes can be formulated with zero VOCs, and can be applied from 30 to 250 mils thickness. These materials have excellent UV stability, as great as 500 percent elongation, and can bridge movable cracks up to 1/8 inch. Cure times for these materials can be engineered to dry to touch from 30 seconds to less than 5 minutes, and have traffic exposure in 2 hours, with full cure in 24 hours.

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A clearinghouse of unbiased evaluation data for steel bridge coating systems is already available, and some 35 states make use of that database. But historically the states have not seen the value in coating concrete, and if they have, their specification considerations have been primarily aesthetic, rather than intended to address the exposure conditions their bridge inventories face.

long-term durability in terms of chloride and moisture resistance as well as weatherability and aesthetics.

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A new era of extending the lifecycle of the nation’s concrete bridge inventory is upon us. After years of transportation industry collaboration, the states are now able to evaluate the efficacy of concrete bridge coating systems, and prequalify them through participation in the American Association of State Highway and Transportation Officials’ National Transportation Product Evaluation Program (NTPEP).

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By: Dee McNeill

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But corrosion protection for prestressed strand still relies primarily on the low permeability of concrete cover for protection of the high load-bearing steel strand. Typical corrosion protection strategies rely on assumptions of little to no cracking in the lowpermeability concrete. Should cracking occur, the high-strength, load-bearing steel strand embedded in prestressed designs carries no secondary corrosion protection. The uncoated high-strength steel strands within prestressed bridges are protected from environmental assaults by just an inch or two of concrete cover.

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Now engineered coatings combined with advanced high-performance concrete provide a critical risk mitigation for prestressed elements that is affordable, inspectable and repairable. These materials are now engineered specifically to adhere to and protect concrete substrates from the deleterious effects of water and salt while also providing other desirable properties of choice such as graffiti resistance and enhanced visibility and aesthetics.

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FOOD PLANT FLOORING

Additionally, standard corrosion protection approaches for prestressed and post-tensioned structures are not inspectable or repairable. Evidence of corrosion deterioration most often shows up in the form of spalling of exterior layers of concrete because of the expansive forces of the corroded steel. Once this level of deterioration has occurred, the options

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This is not an ideal scenario under any circumstances, but now we are contending with the fact that the design life of bridge structures, in general, has been a moving target. While the vast majority of existing highway bridges were intended to meet a 50-year design life, expectations can tilt toward 100-plus years for structures designed today.

The presence of natural airborne salt in coastal environments coupled with the ubiquitous use of deicing chemicals and the realities of sometimes doubled service life demand additional solutions that provide significant durability upgrades at minimum additional investment.

Most civil engineers are familiar with basic concrete waterproofing and sealer type coating materials, which have been used with mixed success on highway structures for many years. These materials include silane- or siloxane-based thin film sealers that provide a relatively short-term solution to chloride and moisture penetration and must be renewed at least every few years to be effective. Also, many bridge owners have used thicker film barrier coatings of various chemistries, but these have generally carried many trade-offs in terms of application properties and performance.

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But it’s not just coatings that have evolved. Newer bridge construction methods of the last 20 years have produced a steel-reinforced concrete bridge inventory with performance properties previously unattainable. Concrete bridge spans are longer and lighter, and more robust geometries are now commonplace because of prestressed and posttensioned girder designs.

for rehabilitation are limited and costly. These factors impact long-term risk analysis and impede a bridge manager from dealing aggressively and appropriately with any early indications of failure among bridges or bridge elements in his inventory. The addition of exterior coatings to the bridge manager’s toolbox in a rational and targeted manner can mitigate some of this existing design-based risk to durability.

IMPACT AWARD

The More Things Change… The More Other Things Change!

CONTENTS

A Shift in Approach

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STI AWARD

More recently, corrosion engineers have focused arguments for investment in durability on technologies that provide increased confidence in performance at a known, palatable cost relative to the costs of contingencies if the investment is not made – unscheduled repairs, system downtime, and ultimately bridge failure and replacement.

The mainstreaming of epoxy-coated rebar for bridge decks and the present move toward institutionalization of high-performance concrete formulations for structural concrete elements has already paid dividends in extending the life of decks and other structural elements. AASHTO is to be commended for taking the lead in this effort and the payoff will be seen when coupled with the participation of bridge owners in the NTPEP program.

CORNELIA MARIE

For years, corrosion engineering decision making has been driven primarily by the tradeoff between initial and life cycle cost. Several factors have worked against the upfront investment in corrosion protection technology. First has been a lack of confident deterioration data. We do know that corrosion will occur in salt and moisture-laden environments, but we do not usually have definitive answers as to when and at what rate it will occur. This lack of deterioration rate data very often takes the steam out of pure life cycle analysis.

The corrosion protection system will be visible for inspection and accessible for maintenance throughout the lifetime of the structure, providing the opportunity for truly preventive maintenance to be performed at a fraction of the cost expected due to structural repairs initiated by internal steel corrosion

2016 NEW PRODUCTS

In either case, the corrosion protection system will be visible for inspection and accessible for maintenance throughout the lifetime of the structure, providing the opportunity for truly preventive maintenance to be performed at a fraction of the cost expected due to structural repairs initiated by internal steel corrosion – a truly revolutionary advancement in civil infrastructure.

ANTI-GRAFFITI COATING

So the question must be asked: would a $10 million investment in an advanced coating system to meet an extended service life requirement of 125 years for a $190 million structure be warranted – just an initial investment of approximately 5 percent to achieve another 25 years of service life for a critical structure?

At the other end of the spectrum, can you justify a few extra coating dollars per square foot for targeted applications such as the beam ends for a state’s bridges to impart a major reduction in risk to the most vulnerable parts of the structures? Presumably the answer to both questions is YES.

IMPACT AWARD

It should be clear, therefore, why the development and active sharing of test- and experience-based data on application and performance of the many material choices that exist today is so critical.

Corrosion protection technologies such as the more inherently corrosion resistant structural materials and durable coating systems must be chosen and installed at an increased cost during construction.

The decision to harden a structure to corrosion most often has required a significant leap of faith for managers with regard to the future deterioration curve of that structure.

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Castle holds a bachelor’s degree with a concentration in chemistry from Morehead State University in Morehead, Kentucky.

FOOD PLANT FLOORING

Castle is the 2013 recipient of the Society for Protective Coatings (SSPC) John D. Keane Award of Merit, which recognizes outstanding leadership and contributions to the development of the protective coatings industry and to SSPC. He is an active member of SSPC; the American Association of State Highway Transportation Officials Subcommittee on Materials (AASHTO/SOM); the AASHTO National Transportation Product Evaluation Program (AASHTO/NTPEP); and the American Society of Testing and Materials (ASTM). Castle has served as chair of the AASHTO/NTPEP protective coatings technical committee and also served two terms on the AASHTO/NTPEP executive committee.

STI AWARD

Previously serving as a chemical and corrosion laboratory specialist for Kentucky Transportation Cabinet, Castle managed daily operations for the chemical section of the agency’s Division of

Sherwin-Williams recognizes the unique coating requirements for bridge and highway applications that must endure challenging environments. The company’s proven coatings solutions are designed to conserve public works budgets while maximizing the service life of coated structures.

CORNELIA MARIE

“Derrick’s extensive knowledge of testing, evaluating and applying coating systems, as well as his deep industry network makes him a valuable leader for Sherwin-Williams,” said Dee McNeill, Director, Bridge and Highway for Sherwin-Williams Protective and Marine Coatings. “Derrick is a great addition to our team who will help to enhance our commitment to service excellence for the bridge and highway market.”

Materials. He was responsible for specifications development and oversight of chemical and physical analyses for materials used in the construction and maintenance of Kentucky’s highway infrastructure.

He also served as a chemist and chemist supervisor during his 20-year tenure with the Commonwealth of Kentucky.

2016 NEW PRODUCTS

Sherwin-Williams Protective and Marine Coatings has hired 20year industry veteran Derrick Castle to lead project development work for the bridge and highway market. As a project development manager, Castle will assist in directing the development and delivery of coatings solutions designed to maximize the service life of concrete and steel structures. He brings two decades of chemistry knowledge and structural steel coatings industry service to the Sherwin-Williams team. He will focus on the bridge and highway market in the Southwest and Midwest United States.

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Derrick Castle brings 20 years of coatings experience to project development role

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SHERWIN-WILLIAMS RECRUITS INDUSTRY VETERAN TO LEAD REGIONAL BRIDGE AND HIGHWAY BUSINESS

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CONTENTS

IMPACT AWARD

ANTI-GRAFFITI COATING

2016 NEW PRODUCTS CORNELIA MARIE

STI AWARD

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M J PAINTING CONTRACTOR

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VIEW FROM CONCRETE BRIDGE

BRIDGE & HIGHWAY VETERAN

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