DECO experts removed coating failure and rust with hand tools, grinders, dust collection system and air quality monitoring. Applied coatings specified designed for pipe gallery asset protection in clean water environment. Meticulous preparation techniques are key to extending the life of the coating. Plant environment was protected with a dust collection system and air quality monitoring.
This project was fast track delivered early. Quality control and quality assurance in confined space pipe gallery was methodically maintained using dry film comprehensive measurements and inspection mirrors.
DECO Method Bins
These were service bins for a national beverage manufacturer. Our Drive Thru & Drop was perfect for these service bins.
National beverage manufacturer rotates four to six bins from assembly line of two hundred. DECO blasted and coated the interior of the bins with a specialty coating for acidic type waste.
The exterior was selected for environment exposure and branding color. These refuse bins are a part of their company branding. Our plant operations were able to maintain the company branding while the bins have asset protection from corrosion.
BINS IN PROCESS
Zinc Beams / C Channels: DECO Method of Deliver Early Coating Options and field touch up was used on this project. Beams and C Channels were dropped at DECO, blasted, Zinc coated, and one finish coat. Each process was measured and documented with cloud based device for quality control and quality assurance. Slip critical ends were protected from blast process and coatings. Finished beams and channels were delivered to airport. DECO did onsite touch up after installation.
Aluminum Panels: This is a prime example of coating panels that can meet fast track project. Some panel coatings required a full 30 day cure before delivery before installation. Metal preparation is careful and meticulous during the etching wash and hand wipe. DECO is experienced with application and adhesion for a variety of panels. Finished panels are racked using clean gloves, covered in breathable protection. Panels were packed and shipped with equal care. Field touch up is rarely needed after installation. DECO has a nearly limitless color palate including a variety of vibrant colors to metals. Quality control/quality assurance inspections are done on each panel. Packing materials selected are researched for coating compatibility. No touch up was needed on the airport panels.
Installation and Touch-Up
Panel Preparation Phase
Pack & Ship
Automotive Floor – Leading Die Casting Plant in the World
DECO was called to resolve floor coating failure on new finished construction floor application. The floor appearance was inconsistent and fork truck traffic left permanent tire marks. The DECO team brought in one of our manufacturer strategic partners to troubleshoot and evaluate floor conditions. After narrowing solution options, DECO began off site mock-ups simulating the existing problem.
Non-negotiable terms included work to done during afterhours, weekend, or shut down; return to full service with truck traffic was 48 hours; no permanent tire marks were to be left on floor; withstand specified cleaning products & process; and limited product components permitted.
Within a short time, DECO presented the best result to the engineers and stakeholders. All of the criteria had been satisfied. An onsite mock up was done, tested and approved. DECO did the project one mobilization over a holiday weekend beginning 3 p.m. on a Friday with total demobilization complete at 6 a.m. Sunday. The entire floor was returned to full service the next day, Monday at 6 a.m. The floor standard became a national standard and DECO has more floors in contract.
Process: 25,000 sq ft of floor space. 3 phase floor grinders with HEPA vacuum system minimize dust and sensitive testing equipment was installed; we then created solid breaks around testing equipment work space; we worked with very limited space access; completed with rapid turnaround time for preparation, installation, and cure time; was fully returned to full operation.
This case was a field rack application converted to DECO Method. We were given eighteen hundred pound automotive racks that the owner had assumed were too large, awkward, and costly for transport.
First, they were staged for field application. Staging challenges were mobilization and cost over runs that occurred from the project at the onset.
The DECO Method was proposed to rack stakeholders which included oversized drop deck transportation to accommodate four racks per load. DECO Method efficiencies captured shipping costs to negate any budget increases.
DECO also provided protection during loading and shipping, resulting in minimal field touch up which DECO included as part of the service. Racks had a factory finish and proper cure time. Preparation and controlled environment were key factors in the success. Some racks required blasting due to existing paint failure, and others required special cleaning of cutting oils from being newly fabricated.
Unique orange color pigmentation required high solid vibrant base which was achieved through testing a series of mock-ups. 34 racks were completed with minimal field touch up. DECO took care of all transportation logistics, delivered finished racks, and had minimal touch up in the field.
Deliver Early Coatings Options for zinc means guarenteeing asset protection. DECO makes the zinc process simple. The driver honks his horn, our security gate opens, the driver pulls up to designated drop, DECO unloads with fork trucks or overhead cranes, then the driver pulls away. It's that simple.
DECO knows the importance of preparation. Our blast technicians have precision skills. Blasting profile is critical to the zinc process. Too much or too little will result in failure.
We use a cloud-based device to document each and every step. If corrections need to be made, they are addressed on the spot. DECO's controlled environment insures quality control and quality assurance is achieved. The attached report is what DECO customers receive to document that the job was done right.
This is a beautiful example of our Deliver Early Coating Options in field operations. Over 300,000 sq ft of fast paced construction schedules were delivered in two phases. Dryfall was applied to entire ceiling deck, a variety of metals were prepped and painted, and CMU/drywall finishes. DECO worked with the General Contractor to begin paint application on trusses and support steel by following immediately behind the roofers and insulators but staying ahead of concrete floor. There are a lot of pro-active logistics to work out for smooth execution and camaraderie with other trades; a DECO core strength. The stakeholders were surprised and excited to see finishes early in the project because typically finishes are one of the final pieces to the construction site; due to DECO's innovative ideas, we Deliver Early Coating Options in the shop and field.
DECO completed each phase ahead of schedule and below budget.
DECO Method - Long Gate
This project was a 40 foot security gate. We were selected due to our capacity to prepare, seal, and coat a large gate of this size in one continuous fabrication. We also submitted drawings to the fabrication company to suspend the gate for coating while balancing the weight to avoid stress on welds.
The outcome developed into a prototype suspension that will be used on future projects. Smaller gates are typically powder coated; however, the liquid coating process and finish is warrantied which gives the owner better value.
The appearance was a factory finish. Even with shipping and installation, no touch up was needed. Our climate controlled environment was a key element in the success of this project.
In this instance, we handled: Masts, Columns, and Panels.
What was required was application on a duplex system for HDG masts and epoxy for steel columns in an active, congested construction site. Weather elements, construction traffic equipment and laborers, construction dust and debris, safety challenges, working from 80 foot boom lifts, and schedule delays were prime examples of why we offer the DECO Method.
DECO safely and successfully completed the project. The DECO Method solves most structural steel and metal coatings for new construction. Safety risks and job site congestion are reduced, while weather events related to coating application are eliminated. Delivery schedules are accelerlated along with quality control/quality assurance and finishing below budgets.
DECO collaborates with the fabricator and stakeholders for shipping along with any field touch up.