One commonality that runs across all coating project types and substrates is the importance of surface preparation. According to the coatings manufacturer ArmorThane, up to 80 percent of all coating failures can be attributed to poor surface preparation, affecting coating adhesion. Inadequately prepared surfaces often result in decreased coating integrity and service life. The exemplary method of surface preparation depends on understanding and adapting to the substrate, the environment, and the coating system’s expected life.
“The more significant the job and the more ramifications of something failing, the more scrutiny that gets put on it,” said Garry Froese, CEO of ArmorThane.
While surface preparation is often seen as one aspect of a broader coatings application project, there can be many steps just within that one phase. Factors to consider include safety protocols, climate control, and pressure washing, to name a few.
Before beginning any physical surface preparation work, contractors should take time to form a suitable plan for all job site safety specifications, both for workers and the surrounding areas. Given recently heightened regulations from the U.S. Occupational Safety and Health Administration (OSHA), this step has only become more significant entering the 2020s.
Ideally, many potential dangers could be engineered out of a project. But for the construction industry, where most jobs are completed directly at the Jobsite, this may not be feasible. This leads to a priority on PPE, with a customized strategy for each job site.
It necessitates a comprehensive risk assessment that considers the different types of exposure, including physical hazards such as drops from heights, slips, trips, falls, cuts and abrasions, chemical exposures, exposure to hazardous particles liquids, etc.
Within PPE for surface preparation, type-CE supplied-air respirators approved by the U.S. National Institute of Occupational Safety and Health (NIOSH) are often essential. Other needs are often blasted hoods, gloves, eye and ear protection, coveralls, hard hats, and boots. Depending on the Jobsite location, fall protection from providers such as 3M and Guardian Fall Protection may be required.
Though water is often used to clean a substrate, too much of it can produce its own set of problems. For instance, if a contractor deals with a leaky roof, adding water may not be the answer. In that circumstance, equipment such as leaf blowers and shovels may make more sense. With concrete slabs, excessive water can lead to poor adhesion and premature coating failures.
Wagner Meters and Tramex Meters are among products’ providers to test moisture levels in both industrial and commercial settings — including in situ relative humidity (RH) testing. For that objective, Wagner’s new C555 Concrete Moisture Meter is among the company’s latest developments. The C555 emits an electromagnetic wave to measure moisture down to 0.75 inches (1.9 cm) below the surface. When combined with an ASTM-compliant in situ concrete RH testing system, the C555 is a novel targeting system that helps contractors place probes in areas where they are most effective.
For roofs, contractors should be prepared to remove and replace all water-damaged areas before applying new roof coatings or coated spray polyurethane foam (SPF) systems. The Tramex Dec Scanner is one example of a mobile, nondestructive impedance scanner designed to survey moisture conditions in roofing and waterproofing systems instantly.
Once the climate is under control, one standard surface preparation method is to use a pressure washer, which cleans the substrate by eliminating old coatings and contaminants. Pressure washers can be used on concrete, steel, and roof substrates, with options including cold- and hot-water e and pressures up to ultrahigh-pressure water jetting.
The selection of pressure washers often depends on the unique needs of each job site. For example, while cold-water pressure washers are becoming for handling basic tasks such as removing dirt and mud, projects involving more complex contaminants — such as grease and grime — may require hot-water models. While the gallons per minute (GPM) and pounds per square inch (psi) of each machine’s pressure must be powerful enough to clean the substrate, excessive pressure can cause its own set of problems by destroying the surface. Thus, contractors have a careful balance to find when selecting tools, and they should pay close attention to the manufacturer’s specifications for the selected coating method. Mi-T-M recommends combining its CBA Aluminum Series cold-water pressure washer with a 20-inch rotary surface cleaner. The surface cleaner is described as an ideal accessory for cleaning flat surfaces. It has strong-bristled brushes for easy glide control, a heavy-duty aluminum handle, and a high-pressure trigger gun for efficient cleaning.
The variety of options possible across all these niche areas directly mirrors how important surface preparation is. By coupling that innovative approach with attention to detail on surface preparation, contractors should be able to blast themselves into success in 2021 and the new decade ahead.
A frequent question from homeowners researching spray foam insulation is “How much does spray foam insulation cost?” Much like buying a car, variable factors can influence the ultimate cost per square foot of a spray foam insulation installation. Below are four things to keep in mind about the cost of spray foam insulation.
Spray Foam Type: What kind of spray foam is being used? Does the project require closed-cell insulation or an open-cell spray foam insulation be used? Open-cell spray foam insulation is more cost-effective than closed-cell and is effective in residential projects in providing thermal comfort, air-sealing, and moisture management.
Quantity: How much material will be needed to complete the job? Open-cell spray can cover more surface area than closed cell spray foam insulation. This is due to the soft, sponge-like surface that expands up to 100 times its initial volume while closed-cell can expand between 40 and 60 times its initial size when applied, meaning more material is required to cover the space. The necessary thickness of the material, dictated by the building code or area of the home, will also contribute to how much material is needed.
Labor: Remember to factor in the price of the spray foam contractor’s labor cost. Unlike painting, spray foam insulation is not a DIY project, and it requires a certified professional to apply the material.
Location/Climate: Southern climates are different from northern climates. Closed-cell spray foam is typically used in areas prone to flooding (since FEMA recognizes the closed-cell as a flood-resistant material). At the same time, open-cell is a great option for southern climates due to its ability to breathe.
Contact:
To find out how much it will cost to install spray foam insulation, the spray foam licensed professionals at ArmorThane would be happy to give you a free estimate for your upcoming project!
SHIVER, a cryogenic test tank developed to assess heat intercept concepts, arrived at Marshall, just arrived. The tank will now receive heat sensors and spray-on foam insulation at Marshall before moving its way to Plum Brook Station for further insulation and trials.
A technical challenge that NASA is working to determine is how to manage very cold liquid propellants to be used as fuel for deep space missions. Heat intercept concepts such as advanced insulation blankets, foam insulation, and vapor-based cooling will be assessed with the Structural Heat Intercept Insulation Vibration Evaluation Rig or SHIIVER at NASA’s Marshall Space Flight Center in Huntsville, Alabama, for application of its first round of insulation.
“We need to get to a spot where we can preserve cryogenic liquid propellants for months to enable higher-performing operations for deep space travel. The state-of-the-art on-orbit storage of a liquid hydrogen tank is a few hours, achieving our current low-Earth orbit needs. We will need much more capable systems for deep space travel,” said Arthur Werkheiser, Marshall integration manager for the Evolvable Cryogenics Project (eCryo), a collaborative project between Marshall and NASA’s Glenn Research Center in Cleveland, Ohio.
SHIVER is responsible for testing technologies to reach these propellants’ storage time in the cold enough environment to remain liquids that are usable as fuels. The tank was manufactured by Didion’s Mechanical in Bellevue, Ohio, and is run by the eCryo project.
Cryogenic propellants are gases such as hydrogen, that when chilled to subfreezing temps and condensed, form highly combustible liquids that can be used to propel space vehicles. Any influx of heat, including heat radiating from a test stand, can raise the propellants’ temperature and prompt them to boil. In normal upper-stage operations, boil-off is considered a lost propellant because it must be discharged from the vehicle to prevent the tank from over-pressurizing.
“If you want to get to Mars, you must prevent boil-off, or when you get there, you won’t have sufficient fuel left to get back,” said Werkheiser. Until now, boil-off hasn’t been a dilemma because the space shuttle and Apollo missions only required to retain cryogenic propellants in flight for minutes or hours rather than the months or years required for deep space missions.
While at Marshall, the tank will have sensors fitted to measure the heat that gets into the tank. The team will then implement spray-on foam insulation (SOFI) to the 13-foot-long tank in Marshall’s Thermal Protection System Facility. A rotisserie-style fixture provides for even spraying of large objects. Following SOFI trimming, the tank will undergo a white-light scan to cover its final dimensions to assist with eventual multi-layer padding (MLI) application. The SOFI and MLI will reduce future propellant storage tank heat leak while on the launch pad, subject to atmospheric temperature and pressure conditions.
“Glenn and Marshall share expertise in cryogenics and have worked on several of these projects together,” said Lauren Ameen, eCryo testing and validation cost account manager and SHIIVER deputy lead engineer at Glenn. “We are looking to develop cryogenic fluid management technologies that can be used in a future in-space cryogenic stage.”
After the spray-on foam insulation treatment, the tank will travel to NASA’s Plum Brook Station in Sandusky, Ohio, managed by Glenn, for assembly, integration, and testing in the B2 test chamber. The assembly will first undergo thermal vacuum testing with only SOFI on the tank surface. This will be the baseline heat load from which to assess future improvements. The tank will then be insulated on the top and bottom domes with MLI over the layer of SOFI and will undergo further cryogenic testing.
When the eCryo project testing is complete, the SHIIVER test tank will be retained as an asset for NASA that can be used for future cryogenic testing needs.
The eCryo project is led by Glenn, managed by the Technology Demonstration Missions Program, and sponsored by NASA’s Space Technology Mission Directorate.
For video footage of the SHIIVER tank and arrival at Marshall:
To learn more about NASA’s Space Technology Mission Directorate, visit:
Spray foam insulation can crank up the performance of your homes—if you do it right. Check out our daily posts on the Foam Insulation and the Foam Insulation Market. We review each company and relay the information directly to you. Join our mailing list and have them sent directly to your email each and every day.
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