Perdue Agribusiness LLC

Working Concrete Deck Area – Soy Processing Prep Room Fully Reinforced Deck Coating – Sika Roof Pro System – Chesapeake Virginia Completion April 2009

Perdue purchased the Soy Processing plant and export facility from Cargill Inc. early 2000s. This plant came along with extensive infrastructure and process improvement needs. The Soy plant prep area includes dry soymeal processing equipment – rotexes (shakers) and other similar screening devises. The concrete deck above was riddled with old obsolete penetrations and other features that allowed water to enter and foul up the process. This was a constant aggravation and cost huge dollar amount for shutdowns clean outs etc. Additionally, it was an irritation to plant personnel who constantly had to stop and clean out rain soaked soy products from their process equipment.

Another strong need was for any deck coating system to have FM approval for fire. Perdue’s risk management company , Global Risk Corporation, repeatedly asked if Perdue could source a system with FM fire approval. Both Global and Perdue’s concern was due to the soy plant being a typical hexane extraction process which means that fire and spark control is not just important – it’s paramount. Hexane is carefully controlled in production; it is very volatile and can easily set off a major explosion resulting in loss of life and property.

Pro Coat offered the Liquid Plastics (now Sika Corp.) Decothane fully reinforced waterproofing system. This is liquid applied, fiberglass reinforced membrane at a total 100 mil thickness. The reinforcement fabric is very unique; when the strands make contact with the coatings its bonding breaks down making the actual fiber stands completed “conformable”. In this regard it wraps perfectly around odd shaped penetrations and even drain openings, thereby creating a totally monolithic coating / waterproofing membrane.

Sika’s Roof Pro is in fact FM approved for fire (See video below). When it is introduced to high heat source – it actually emits moisture vapor and helps put the fire out! Global Risk Management provided their letter of approval and Perdue proceeded with installing the system over their soy process area, which has stopped leaks and provided an outstanding work deck for years since.

 

 

Prior to starting this project Pro Coat had a major undertaking with removal of existing roof coatings. For some unknown reason the previous owners attempted to use an asphaltic product on the roof. By the time all removal of this product and other tar sealing coatings products, Pro Coat removed in excess of 30 tons worth of obsolete materials & weight off of the roof.

Pro Coat formed and installed rebar, reinforcement in all the voids & obsolete penetration openings. They poured and infilled with concrete eliminating old openings. Likewise, they trowelled on concrete to existing penetrations in order to provide a smooth transition to receive the waterproofing membrane.

The entire surface was either ground or sandblasted to provide cleanliness and proper profile. All metal was primer using Sika EP / metal primer. Concrete was primed using Sika damp tolerant primer. The first embedment coat was applied at 50 mils and fully reinforced with their Reemat Premium scrim. The intermediate coat was applied at 30 mils, and final “wear” coat at 20 mils with an aggregate broadcast for non-skid / safety and added life & wear.