• This existing manufacturing facility, located in Tulsa, Oklahoma, needed to install a fast set floor coating in order to eliminate constant concrete dusting and harden the surface of the floor. A major concern was down time! While epoxy floor systems were considered they were not accepted due to their long cure times, as well as material and labor cost. Instead ANVILDECK was chosen because of it’s price and rapid turn around time frame.
• The size of the facility was 20,000 SF, however, only 3,000 SF was scheduled for resurfacing. The entire project was to be completed in 5 different phases. All work needed to be done in one long workday.
• Once installed the floor had to be reopened to both foot and fork lift traffic within 2 hours.

 BACKGROUND:

• The owner had previously tried different penetrating sealers and hardeners with no success. Elastomeric materials were looked at, but because of all the heavy fork lift traffic, were not considered a feasible choice. The existing floor had many spalled sections and random cracks which required repair. The owner wanted to use his employees to do as much of the work as possible, with exception to the actual surface preparation. This required special steel shot blasting equipment and experienced personal, therefore, the owner decided to hire an outside contractor to handle this phase of the repair project. However, once the floor had been properly prepared the owner was able to save a considerable amount of money by using in-house personnel for the actual application of AnvilDeck.

 MATERIAL:

• Product specified: AnvilDeck and ElastoFil 75. AnvilDeck is a 1:1 ratio urethane/epoxy coating that can be used as both a primer, rapid concrete repair material and coating. ElastoFil 75 is a 1:1 ratio, hybrid polyurea, crack and joint repair polymer for interior concrete repair. During this installation AnvilDeck was used to repair concrete spalls and then to coat the specified 3,000 SF area. ElastoFil 75 was used for the concrete crack and joint repair.

• Prior to the installation, the entire floor was shot blasted to obtain the recommended profile. Once the surface preparation was completed and all the random cracks were ground out and filled with ElastoFil 75, (manufactured by ESI) the company’s employees did the rest of the floor repairs and actual product installation.
• Installation of AnvilDeck was made using 18-inch medium nap, commercial paint rollers and rubber squeegees. AnvilDeck was installed in a four-coat process. The 1st coat or primer coat was mixed in 2˝ gallon buckets for 15 seconds, then poured down and spread out using the rubber squeegees, followed by enbloyees with paint rollers. The roller portion of the installation insured that the AnvilDeck was evenly applied to the surface and, also, eliminated ponding of the material.
• Once the primer coat wss laid down, the crew immediately began applying the second, third and final top coats to the specified area. The owner did not want sand or other aggregate broadcasted into th esurface for non-skid purposes, however decided to have a smooth finish for easy cleaning. “NOTE!” To achieve a non-skid surface, broadcast sand or other media into the third coat and lock in media with the fourth and final coat.
• Due to the viscosity of the material, AnvilDeck is designed to be a thin film, extremely fast curing, hard, durable coating for any concrete surface. This product is aromatic in nature; therefore it is not color stable and will have a tendency to darken up.
• AnvilDeck is “NOT” designed to compete with highly cosmetic, more expensive epoxy systems , therefore its best use in tough manufacturing plants, mining facilities, machine shops, automotive repair stores or areas where concrete floors are subjected to severe abuse. In these applications, AnvilDeck offers durability and longevity, and is inexpensive and easy to install. It can be easily recoated to upgrade cosmetics.
• Because of its unique chemical make-up, AnvilDeck can be recoated at anytime as long as dirt, grease, and petrochemicals have been removed from the surface area. “Priming is not required.”
• Once installed, this floor was reopened to heavy traffic within hours.
• Project start and completion date August 24, 2002