Project: Waterproofing & Restoration of Allstate Information Management
In the heart of North Jersey lies a large city that served as a hub to send our country flying into the industrial age. For decades, Paterson maintained its prestige as a booming manufacturing city, one of the largest in the United States. But as business changed and buildings aged, this once flourishing area has seen many of its buildings transform into historical landmarks from the industrial era. Allstate Information Management is sitting inside of one of these infamous buildings with over a century of history under its foundation.
Allstate Information Management approached Alpine Painting with one request; make this aged building safer to work in and around and prevent any water from penetrating its walls. While that may sound like a simple task, with a building that once served as a Plant No.1 of Wright Aeronautical Corporation to develop and manufacture aircraft engines for the inventors of flight, more hazards than meets the eye were bound to be faced. Sections of concrete were falling from the structure's elevations, making it dangerous to walk the buildings’ perimeter. With the missing sections of concrete and age of the edifice, creating a water tight, safe building was the number one priority for our customer. Allstate Information Management stores paper documents for hundreds of clients inside and could not have the risk of any water penetrating into the storage areas where this documentation was kept. In the past, Alpine has worked with Allstate to waterproof some of their properties but this will be the largest project Alpine has taken on to restore this building back to its original glory.
Prior to beginning any work, Alpine had to first assess the best and safest way to approach this project. Heights were an obvious hazard but throwing in potentially falling concrete posed an entirely new threat. All workers were required to wear hard hats at all times while on site and unless absolutely necessarily, workers were told to stay away from the walls while on the ground. In addition to the hazard of the concrete falling, concrete already on the ground posed tripping hazards and more significantly, they posed a hazard to moving lifts around. To eliminate this hazard, all work areas were constantly cleaned and a spotter was used while moving the lift. All workers were always tied off while inside the basket of any lifts on site. Daily toolbox talks were conducted to review any specific hazards that may be faced that day and to prevent workers from becoming complacent. For all work tasks, workers were also required to wear safety glasses and gloves, especially during any spray application that was being done. Since grinding was present, workers were instructed to wear face shields and/or safety glasses. Because of these efforts, no incidents occurred on this project, despite the elevated risks. Once the safety was addressed and the plans were written, work could begin on the project.
Phase one of this project was make this massive stretch of warehouse safe and secure. Alpine was responsible with finding any areas where the concrete was not secure or cracking, repair the masonry, repoint any brick that had been damaged, and apply a waterproof coating over the top. Over the past century, this facility has taken a beating from the environment, resulting in large, gapping areas of concrete that were deep enough to expose the rebar foundation holding the building together. Alpine was also tasked with exposing the rebar and applying an epoxy mastic coating to assist in preventing any future corrosion from occurring.
To ensure our new coatings would bond properly, an adhesion test was completed to multiple areas. We found that the vertical columns failed the adhesion test. Because of this issue we changed our scope to use high water pressure to strip the existing coating from these areas and fully priming the columns with a specialized bonding coating. Alpine's employees pressure washed the remaining building areas, using approximately 2500 psi, to clean all accessible areas of loose and peeling paint. Using grinders and hand tools, areas of the building were prepped according to SSPC-SP2 and SSPC-SP3 to remove any loose & peeling paint and rusted areas. All prepared masonry was primed using Sherwin Williams Loxon Conditioner and all metal and rebar areas were primed with Sherwin Williams Kem Bond Rust Inhibitive Primer. The preparation of the concrete took care of the danger from the falling and cracked areas and the conditioner was the first step in the water proofing system that was to be applied. The masonry conditioner acted as a tie coat to the bare and previously painted surfaces to help assist with obtaining proper adhesion. The next step to waterproofing required that all window trim or gaps be filled with High Performance Paintable Caulk. This product, which had a 25 year warranty from Sherwin Williams, would fill in large gaps and cracked areas that a standard coating would not fill in. The caulk would adjust to changing weather conditions without cracking or opening holes but allowed it to be painted to ensure a smooth finish and additional water proof protection.
Proper coating and color location was vital to a successful project. A building rendering was created to outline which building sections were to receive each color. A separate painting agenda was constructed to ensure our craftsmen knew exactly where each product, how many coats and what color was to be applied in each building bay.
After all the preparation work was completed and the bonding conditioner was applied, our craftsmen spray applied and back-rolled the high build water proofing system. Using brush, roll and spray, Alpine’s team applied two full coats of Sherwin Williams Loxon XP Waterproofing coating to all painted masonry areas. This coating was applied with a flat, smooth finish. Any metal trim and window frames received a full coat of Sherwin Williams Industrial Urethane with a gloss finish to really make those areas pop and stand out. All unpainted brick surfaces were sealed with a clear penetrating waterproofing coating made by SealKrete.
The original timeframe to complete this job was about two months, which Alpine employees were able to complete on time and budget. Allstate asked Alpine to install block to a boarded up large opening on the penthouse floor. This was added to the scope of work and Alpine was able to fill the rough opening with new CMU and recoat the area to help it blend in with the rest of the building.
Overall, this project was extremely successful. Not only did Alpine provide an existing customer with another great experience, but they were able to bring life back to a piece of history and help it survive another century under its new identity.
Sherwin Williams Loxon Masonry Conditioner (Approx. 45Gal)
Sherwin Williams Loxon XP Waterproofing Coating System (Approx 300Gal)
Sherwin Williams Kem Bond Rust Inhibitive Primer (Approx, (Approx 10Gal)
Sherwin Williams Pro Industrial Urethane Alkyd Enamel (Approx 15Gal)
Seal Krete Original Waterproofer Clear Sealer (Approx 55Gal)
Sherwin Williams Stampede High Performance Sealant (Approx. 4 Cases)
Charlie Schiermeyer, Facility Manager for Allstate Info
Rich Trefz, Technical Coatings Expert, for Sherwin Williams
Ed Bain, Alpine Painting’s Lead Project Manager
Our diligent and hardworking craftsman
Joe Cardinale & Pete Maynard of Sunbelt Aerial Rental Company
www.allstate-im.com General Information