Case Study

Procedure & Observations:
This is a continuation of the project started in October 2004 whereby Pavemend was utilized as an overlayment by ISL to provide an aesthetic, functional and durable flooring solution for Metal Container Corp. After multiple trips to the site and extensive evaluation by CERATECH’s field engineers and R&D staff, a single product was developed for the specific needs of ISL and Metal Container.

The purpose in developing the product specific to the need was to provide the end user with a solution not otherwise attainable in the industry. The subject floor, which has been reported on extensively by Larry Francis, is contaminated with oil residue and other hydrocarbons from years of maintenance related to the operation of the aluminum can stamping plant. After exhaustive study and two previous test placements, CERATECH’s collective recommendation was to alleviate the blocking agent that was being installed on the contaminated host concrete (Aquafin’s SG2) as a preparation for placement of an overlayment, in this case Pavemend, clean the concrete and place PaveMend directly to the host material. The conclusion was that the SG2 was not bonding entirely to the contaminated host and thereby breaking loose. Pull tests confirmed that PaveMend was bonding to the SG2 and silica sand underlayment. CERATECH R&D and field engineering are of the opinion PaveMend will bond to the host material once cleaned with an agent designed to eliminate the oil and other hydrocarbons.

Mack Queen of ISL located a product know as “KT Surface Oil and Gas Microbial Cleaner” designed for this purpose and utilized it to cleanse the floor prior to placement(see pix). The area in which the test was conducted did not appear to be severely contaminated. A small amount of oily, foamed substance appeared to be removed during the cleaning process.

The purpose of placing the specially developed Pavemend TRE™ is twofold; prove the bonding capabilities of the product and provide the aesthetically pleasing end product the customer desires. The original plan was to provide three products with slightly different characteristics for consideration in a 15’ X 15’ test area split into three areas of 5’ X 15’.Since the decision was made to provide only one product, a 5’ X 15’ test area was poured.

A specifically formulated PaveMend TRE was developed and supplied in an amount to conduct the 5’ X 15” area. The ambient temperature within Metal Container at the time of placement was 82°F. Water and material were in similar ranges. The decision was tousle cooler water and 70°F water was procured from outside the building. The first two 45lb buckets of material were mixed with the 70°F water with mix times just shy of 10 minutes to reach critical mix temperature of 90°F. The next four buckets were mixed using 80°F water as a production consideration and achieved mix times between 6-7 minutes. The material was placed using a grade rake and then troweled smooth.

Pete Bruce and Larry Hall were on site to conduct the mix and oversight of the placement. Pete Bruce did a masterful job in placing the product and including ISL’s personnel in the process. They appeared to find the application and performance characteristics of the Pavemend TRE™ formulation very interesting, particularly the ability of the product to be troweled and reactivated. Pictures of the placement after initial set are shown below.

Conclusion:
ISL will grind and polish the test area beginning Thursday, 13 January (36 hours after initial set). Our conclusion is that by providing a product that will bond to the host concrete without having to use a blocker/silica sand preparation will save the customer time, money and yield the desired aesthetic results of the floor rehabilitation. In doing so,we will receive an opening order for enough material to complete Phase I of the Metal Container project of 35,000 square feet. In addition, we will then be in a position to offer Pavemend as a remedy to Anheuser Busch on a global basis