Alpine needed to remain flexible and responsive to the tenant’s needs to avoid overwhelming their daily operations. This involved many walkthroughs and 8001 and 8003 Industrial Drive in Carteret, New Jersey are both concrete tilt-up buildings for Alpine’s client, Prologis. One building is an Amazon fulfillment center and the other houses two tenants, Graybar, and Roca Tile USA. These were capital improvement painting projects on behalf of the owner, Prologis.

The scope entailed cleaning the surfaces, priming, and repainting the building. The added scope was to remove the vertical expansion joints. Alpine removed and replaced all the caulking to create a watertight environment and make it aesthetically appealing with the new coating. The challenge for this assignment was working around a large number of vehicles and activity surrounding these two very large facilities.

The assignment involved a ton of coordination with the buildings’ tenants so that Alpine would not interfere with their operations. Their goal was to work around the tenants’ activity and not impede their ongoing operations while at the same time adhering to the completion schedule.

The History’s in the Foundation

8001 and 8003 Industrial Drive are relatively new buildings constructed in the 21st century. Conditions were very sound as these were relatively new warehouses that were being repainted for the first time.

Surface preparation for the project involved power washing the exterior to clean the surface and remove contaminants prior to painting. Scraping and loosening flaking paint, wire brushing corrosion or rust, and removing the existing sealant to allow for new sealant installation were other surface prep actions taken.

PCA Standards

P17 – Field Painting of Smooth-Faced Tilt-Up Concrete. This was to set expectations and a clear allowance for how many masonry repairs would be made based on those identified during the walkthrough before the start of the project.

P22 – Cleaning Surfaces Using Pressurized Water. Utilized high-pressure washing at approximately 3500 PSI prior to painting.

Painting Through the Challenges
Challenges on this project revolved around coordination. Amazon thrives on efficiency to meet their end-customer delivery expectations so it is especially challenging to identify with them on a daily basis enough workspace that would not interfere with their work patterns.

Alpine needed to remain flexible and responsive to the tenant’s needs to avoid overwhelming their daily operations. This involved many walkthroughs and ongoing conversations with their facility managers. Numerous times, Alpine had to make adjustments after setting up for the day to accommodate Amazon's busy schedule and high level of activity.

Another challenge was the size of the project which took place in a massive space, with many moving parts. Therefore, the team needed to be aware of every move required and to thoughtfully execute it to ensure the safety of all involved.

Also, the ideal temperature and visibility were necessary, oftentimes working 10-hour days to get ahead of any unexpected Amazon request or changes the following day. Working in the middle of summer meant that Alpine had to ensure the crew had the appropriate attire and remained hydrated. Conversations informed the crew to take breaks and other safety measures when working outside in high temperatures.

The project was challenging because it required the Alpine team to work in an active environment. Safety was the priority as there were many types of vehicles moving about the work area at any given time. Alpine had safety personnel communicating with the crew working on lifts and evaluating where they would need to work next.

Another challenge of the project was the potential for overspray in the surrounding area. Great caution was taken to not create overspray to vehicles stationed near the work area. They did this by being aware of wind patterns and pedestrians unaware they were walking into an active work area. Patience and diligence were required by Alpine as information shared with facility managers did not always travel down the appropriate chain. In a number of instances, a closed-off work area had Alpine’s cones removed and vehicles parked there erroneously.

Alpine made an effort to always convey the reason why disruptions to an area needed to take place – oftentimes, for the protection of those affected – which helped to increase cooperation. Ultimately, a rhythm was established to get everyone on the same page.

As with all exterior projects, Alpine’s work was dependent on the weather. They needed to track rain forecasted and humidity levels to make sure products were applied according to the manufacturer's recommendations

Complimentary Colors
Alpine’s top priority, aside from safety, was keeping the Prologis’ customers happy. Alpine created a positive relationship with the client’s end-user Amazon, Prologis’ largest tenant.

Alpine prioritized keeping all tenants happy throughout the project, minimizing the need for any of the tenants to contact Prologis with any concerns. Alpine has worked with Prologis for a long time so they know how to best work with them.

Commonly on these projects, you have a schedule but it changes regularly so Alpine had to be flexible. Knowing this ahead of time, Alpine developed a plan A that was shared with the tenant and also a plan B in the background, in case they needed to pivot.

Alpine has been working with Prologis for over a decade and typically services over 30 of their buildings per year (a number that has grown over time.) As with all clients, Alpine’s reputation with Prologis is they do what they’re told, and with a smile on their faces.

The Alpine leadership trained its staff to put the client first, always being an active listener and working around the client’s needs. Through its ongoing relationship with Prologis, Alpine has made it clear they are a capable contractor that is quick and thorough in its work, always observing PCA standards and industry best practices.

No Paint, No Gain

• Painting brush, roller &/or airless spray

• Sherwin Williams KemBond, Rust Inhibitive Primer

• Sherwin Williams Bond-Plex Water-Based Acrylic Coating

• Sherwin Williams Pro Industrial Urethane Alkyd Enamel, Gloss Finish

• Sherwin Williams Sher-Cryl HPA High Performance, Semi-Gloss Coating

• Sherwin Williams SuperPaint, 100% Acrylic Latex, Flat Finish

The Sherwin-Williams products used were specified in advance. Alpine uses these products regularly and they perform well. Alpine used electric caulk cutters when removing the vertical expansion joints. This is not a tool many painting contractors are familiar with as they usually use knives. An electric caulk cutter is a power tool plugged into the basket of the boom lift that has an oscillating blade on the tip. It cuts through the sealant quicker and with a lesser impact on the craft worker.

Safety Plan

Alpine created a Jobsite Hazard Analysis (JHA) to make sure all safety concerns were addressed. Fall protection was used to make sure harnesses and lanyards were implemented when utilizing all aerial equipment. The proper PPE was used to ensure crew protection while using certain tools on the project. Also, hazard communications were implemented to protect against moving equipment and to create a secure environment that protected any person entering the work area.

One of the main concerns was that the buildings were fitted with solar panels so Alpine needed to be very aware of wind patterns when spray painting to avoid over spraying and having any unintended surfaces become contaminated with paint. Alpine’s main concern is always safety. Toolbox talks that changed over time took place throughout the project. The team leads also made sure to communicate regularly with the tenants and to keep the Prologis client updated.

Hard Works Paints Off
The project was one of the largest projects completed by Alpine from a concrete tilt perspective. Having to complete two very large buildings at the same time, Alpine had to assemble a very large crew of 20 men to work 7 days a week to get the project done as efficiently as possible before the cold weather set in. Alpine also needed to get this project done as quickly as possible in order to move on to the next Prologis assignment on schedule, which the client expected regardless of the unique size and scope of this one project.