Gilbert Engineering

Gilbert Engineering

Gilbert Engineering, a leading manufacturer of coaxial cable connectors, located in Glendale, Arizona was experiencing problems with their plant floor. For nearly 15 years, bare concrete at this site had been subjected to plating shop operations. This included daily exposure to heavy forklift traffic and process chemicals including: sodium hydroxide, sulfuric hydrofluoric and nitric acid as well as sodium dichromate and cutting oils. The plating shop floor exhibited extreme corrosion and was constantly wet and very difficult to clean. In an effort to resolve these safety and operational problems created as a result of the deteriorated flooring, Gilbert Engineering took action to resolve the matter.

Gilbert Engineering planned ahead to minimize losses due to nonproduction. Prior to shutting down the plating line, production was increased to provide a surplus inventory. In addition, a plating line was temporarily relocated to a different part of the facility to manage "must need" parts. Some plating was subcontracted to smaller, local plating shops.

To insure that the protective flooring system to be installed would meet their exact requirements, Gilbert’s engineering team worked very closely with a General Polymers certified contractor, Arizona Concrete Repair and the General Polymers Flooring Representative. Together, the project team identified the following needs:

1) Isolate each plating line from adjacent areas and walkways.

(2) Isolate selected areas within each plating line to eliminate various chemicals from merging together. This helps prevent potential hazards as well as eases their waste treatment requirements.

3) Create a "collection" point within each isolation area. This is for ease of collection of spills and/or wash downs.

4) Install protective coatings throughout the area.

(5) Minimize down time.

Precise locations of the plating lines were decided. Extensive surface preparation including two high pressure steam cleaning passes, scabling of eroded areas followed by shot blasting of the entire area was required due to oil contamination of the slab.

< Next, 4" or 6" berms were installed at the perimeter of each plating line and within each isolation area to prevent chemical migration and ease waste treatment. Berm height decisions were based on individual area contaminant requirements. To minimize down time, berms were constructed of solid CMU Block. General Polymers TPM #115® was used as the block mortar over primed block and substrate. All containment berms were installed and cured in one day, an impossibility had cast-in-place concrete been selected.

Isolation areas were then repitched (sloped) to ease collection of liquids. The easiest and quickest way to achieve slope was to repitch in one direction with collection along one common berm. The repitch material could be either cementitious or polymer-based. Cementitious products while cost effective, require a hydration period, thereby increasing down time. Instead, Arizona Concrete installed TPM #79 Epoxy Slope and Fill Mortar.

Finally, 1/4" Novolac Epoxy overlay TPM #12 was placed over the entire project with skid-inhibiting surfaces on traffic aisles only. The overlay was wrapped up, over and down the CMU Blocks, ‘locking’ the block in place. They are held in place better than a concrete curb with steel dowels. The entire project was completed in 7 working days.

According to Gilbert’s plant superintendent, "We couldn’t be happier with General Polymers flooring or their local contractor, Arizona Concrete Repair. The floor and pits which have been in service for over a year have performed to expectations." The system continues to perform despite the fact it is subject to aggressive chemicals, heavy fork lift traffic, steel wheeled carts, and an aggressive scrubbing routine.

Find out how we can help solve your difficult flooring problems. For more information call 800.543.7694 east of Rockies or 800.624.5041 west of Rockies.