How did DU-ALManufacturingCompany solveasevere metalroof leakingproblem?

ASTEC Ceramic Insulating Coating

"We've had an extreme leaking problem on the 60,OOO-square-foot metal roof ofour main plant," said Edward M. Jankowski, manufacturing engineer for DU-ALManufacturing Company, Sioux Falls, South Dakota, a leading manufacturer offront-end loaders for farm and commercial tractors, trenchers, backhoes andmanure spreaders for the agricultural industry.

"The problem resulted from constant expansion and contraction of the roof's steelsheets in summer and winter. Bolts holding the sheets together would elongate,causing leaks. In fact, we had leaks all over the place:' Mr. Jankowski said.

"We tried numerous coatings...nothing really worked. Most would work for awhile, but then back to the same old problem. Then, we heard about ASTEC.I investigated the product quite thoroughly, including contacting a dealer inDenver and several people there using the coating. Everyone seemed more thansatisfied, so we decided to give it a try," he added.

"We've been very impressed with the results," Mr. Jankowski said. "ASTEC solvedour leaking problem, and the leaks don't return. One of the reasons is that ceramicinsulating particles in the coating keep the roof surface at the same relativetemperature, thus virtually eliminating any expansion and contraction or thermalshock that causes leaks. This has greatly lowered our yearly maintenance of theroof, and the insulation value actually helps save energy... temperatures inside thebuilding are cooler in summer. We would not hesitate to recommend ASTEC toanyone who asks."

According to Tom Foster, co-owner of Energywave Systems, Inc., the localcontractor who applied the ASTEC coating for DU-AL, "The quality of this productis incredible. It's a great waterproofing system, extremely durable, and easy towork with. And its ability to insulate ... I call that the cherry on top of the cake."

o other roof system like it

ot only does A TEe wnterproofnnd insulnte, it nlso preventscorrosion; protects ngninst UV,cltell/icnl, wentlter nnd winddnll/nge - nil for ns little nsItnlf tlte cost of otlter systell/soffering sill/ilnr benefits.

Find out for yourself.For FREE literature, includingtest results, call today!

1-800-223-8494

Edward M. Jankowski ICC The Total SolutionThe Paint That Insulates103 Main St., Binghamton, NY 13905

Rainier Cold Storagenot only improvedtheir looks, butalso reducedenergy andmaintenance costs .. ~

withASTEC"Thanks to ASTEC, we have a very nice looking facility, our energy costs are

lower, and we're saving maintenance costs on our equipment," said MichealRoberts, vice president of Rainier Cold Storage and Ice, a 92,OOO-square-footcold storage and processing facility in Seattle, Washington, which holds some28 million pounds of frozen seafood.

"I was skeptical at first that this product could do everything that themanufacturer claimed ... especially the insulation aspect," Mr. Roberts said."But we needed to have our facility painted anyway, so we decided to try it."

ASTEC features ceramic insulating particles which have outperformed upto four inches of R-20 insulation in certified tests.

"We're very happy with our decision. The coating works as advertised. Ourengineering department reported that the plant is consuming less energy, andour cooling equipment doesn't have to work as hard to maintain the tempera­ture. In fact, ASTEC has cut our refrigeration costs 10 to 15 percent," he added."Plus our maintenance costs are lower because the equipment runs less anddoesn't have to work as hard."

In addition to the insulation and maintenance benefits, ASTEC has improvedthe looks of the 7-story building. "I get compliments from people I don't evenknow who have noticed we've painted the building," Mr. Roberts reported."ASTEC also solved a condensation problem we had on our back dock."

According to Harley Simonson, co-owner of Lundeen and Simonson, thecontractor who applied the ASTEC coating for Rainier, "We've been in the coat­ings industry since 1965 ... ASTEC simply outperforms any kind of coating thatwe've been involved with."

,

ICC

One coating that does it all!

ASTECww~probkmsonw~~

ceilings, metal and other roofs, pipes,rruu:hinery, ducts, boilers, ovens, etcTough, durabk ASTEC• Waterproofs - stops leaks• Neutralizes rost - prevents corrosion• Protects - resists uv. chemical,

weather, and wind damage• Prevents thermal shock - minimizes

roofmovement• Jnsul.at~ - cuts energy costs

All for as /iltk as half the cost ofother systems offering similar benejiJs.

Find out for yourself.For free iiterature, including test results,caU todlly!

1-800-345-5306----~-----

1_IIUng ColUnga CorJInUonThe Paint That Insulates954 s.dI H..., 41. In.... FL 32650

Auvil FruitCompany SolvesRefrigerationProblem...with

ASTEC Ceramic Insulating Coating

When Auvil Fruit of Orondo, Washington decidedto store cherries in their building #3, they hada problem. Their refrigeration system wasn'tkeeping the temperature cool enough.

According to Walt Hough, warehouse productionmanager, "Our building #3 is all iron with agalvanized metal roof. The building was originallydesigned to store apples in the late fall or earlywinter, not cherries in the middle of the hotsummer. So the refrigeration system was quiteinadequate. We had four compressors runningconstantly and we weren't able to keep thefacility cooL"

"One solution was to add more refrigerationequipment. However, that would be veryexpensive," Hough said. "Then I came acrossinformation on aceramic insulating roof coatingmanufactured by Insulating Coatings Corporation.It looked good."

ASTEC is a fluid-applied coating with ceramicinsulating particles which have the ability toreflect, refract and dissipate heat. It hasoutperformed up to four inches of R-20 insulationin certified heat-gain tests.

"I'm probably as skeptical as anybody you'llfind," Hough commented. "So we decided to dosome tests of our own. We put down a four- tofive- foot square patch on the roof of our buildingto conduct some' temperature tests. I did anumber of tests... one on the surface temperaturesoutside and also one through our insulationwith temperature probes from the inside. Thetests were particularly telling. We placed the

probes through the roughly three to four inchesof spray foam urethane, right up to the metal onthe inside of the roof. On hot sunny days withoutside temperatures approaching 100 degrees,I could show up to 40 degrees differencebetween the ASTEC test area and unprotectedareas," Hough said. "After seeing these results,we decided to go ahead."

Working through contractor, Crown CoatingCo., Oroville, Washington, Auvil coated theapproximately 7500 square-foot metal roofsurface of building #3. "We had about 100horsepower of refrigeration in the building,"Hough reported. "That's divided by fourcompressors with approximately 25 horsepowereach. And this wasn't enough. When wefinished coating the roof, we could keep thetemperature around 35 degrees... even in thehot part of June and July with less than 75horsepower. We now need only three of thecompressors running only part of the time."

Hough said, "Our main goal was to reduce heattransfer. From this standpoint, ASTEC is a realsuccess story. It did everything the contractorand ICC said it would do. To me, it is avery goodroof coating. Not to mention it looks great,with a nice clean, white appearance. I wouldn'thesitate to use or recommend this product again."

In business for about 60 years, Auvil FruitCompany runs a700-acre orchard that suppliestop quality produce. They grow, pack andship Granny Smith, Gala and Fuji apples andRainier cherries.

o otller roof system like it...

III additioll to its i/1Slllatioll qllalities,A TEC offers a variety ofothervaillable bellefits:

• Stops leaks - Pn'l'ellts thermal shock• elltralize rust - Fi I1ts corrosioll• Protects - Resists Uv, chemical,

weather alld whld damage• Lasts - Offers olltstalldillg elasticity

alld e1ollgatioll properties to prevelltcrackillg, peelillg or bli terillg

PillS ASTEC is /1011 toxic; easy to applywith brush, roller or sprayer; alld bOlldsto difficilit sllrfaces... All at savillgs asmilch as 50% vs. competitive soilltiolls.

olllld illterestillg?For free liternt//re, illel//dillg testres//lts alld additiollal s//ccessstories 011 other prod//ct //ses alldbellefits, call today.

1-800-223-8494

ICC The Total SolutionThe Paint That Insulates103 MalA St., Blng"-", If 13905

Rust, Leaks,or ASTEC® Ceramic

InsulatingCoatings

ASTEC® solves corrosion and leaking problems whilereducing interior building temperatures...

• Inhibit rust-Prevent. moisture and chemical corro ion.• Prevent roof movement-Eliminate thennal

shock (expan ion and contraction of metal heets) by keepingr of urface at the same relative temperature.

• Protects-Resists V. chemi al. weather, water and winddamage.

• In ulate -Outperforms four inches of fiberglass insulation inheat gain lest .

• Last ut. tanding elongation and elasticity propertieprevent cracking, peeling, or blistering. Provides durable.long-lasting fini h.

• pplie ea il -Applie with bru h. roller or sprayer andbonds to difficult urface.

• Proven effective-Covering millions of quare feet in a widevariety of application..

In addition to roofs, use ASTEC~ on interior/exterior walls,ceilings tanks, pipes, duct, boilers, machinery and more.

ICCIn ulating Coating Corporation103 Main Street, Binghamton, Y 139051-800-223-8494

To find out more, call your local authorized dealer.

Best of all, ASTEC® costs Ie s than other coatings offering similar benefits!

undercoat was sprayed over the entire roof, and a topcoatwas added.

Shortly after the roofing material was applied. El 1110

brought some of the heaviest rains that that part of thecountry had seen in many years. Surprisingly. 'there wereno roof problem. "Thi product is flexible, which is im­portant. yet it dries to a durable surface that won"t tear orcrack," says Eddy. "We haven't had any problems since.We even found that the insulating propertie of thi .product have favorably affected the heating and coolingcosts of our facility. '

FOCUS ON FACILITIES

EI Nino tests new roof

~e Anaheim (Calif.) Convention Cen­

ter had a severe leaking problem on it80,000 sq-ft corrugated roof. "Over

the years, thermal hock or heating andcooling of the roof's surface caused screw'to pull up, and cracks formed between theseams." says Jim Eddy, stores supervisor incharge of purchasing and contracts for thecon ention center. "Some screw holes wererusted, and rUSl had formed on other areaof the roof. Leaks posed big problems allthe way down to the convention floor," headd.

Management chose Astec (Binghamton,.Y.) ceramic insulating coating to repair the

roof. Astec is a durable, fluid-applied re­roofing system that stops leaks and preventsmoisture, absorption. and corrosion. The A new roofing system on a convention center survived theroofing material als resi ·ts damaging ultra- EI Nino fury with no damage.violet rays, while protecting against atmos-pheric chemical deterioration. Ceramic insulating particlegive the coating the ability to reflect. refract. and dissipateheal. Thi. eliminates thermal shock, which causes manyroof leaking problems.

Later, the entire roof was power washed to remove looseparticles. Then, to make sure everything wa tight and se­cure. fasteners were tightened and new fasteners addedalong with waterproof tape over all seams and larger" epa­rations in the metal. A waterproofing membrane was ap­plied over all tape and fasteners, and a coat of the roofingmaterial was applied over the waterproof membrane. An

Reprinted from Engineer's Digest Magazine, March 1999

,

Reprinted from Metal Architecture magazine, August 1992

Roof Recoating System Saves Big DollarsFor Indiana Building Management Company

ASTEC·, a fluid-applied ceramic coating system manufactured by Insulating CoatingsCorp., Inverne ,FL. was specified to re-cO\'er the roof of a 98,000 sq. ft. warehousebuilding in Ft. Wayne, I . The building's management company wa 0 plea ed with theresult, it has since specified the system to re-coat another of it buildings.

Success storie cOl1linue to surface regard­ing the application of recoating sy tems overold. leaking metal roofs. One of the latest in­volves Maintenance Management Co. Inc .. aFort Wayne, IN-based business that maintainsand operate a number of commercial and in­dustrial buildings.

In an effort to solve the severe leaking andrusting problems plaguing a number of it olderbuildings, the company okayed the applicationof a eramic insulating coating system on a100,000 sq. ft. roof area. 0 succes ful was theproduct in stopping pOlentially damaging leak­ing, the company recently okayed its use onanother 75 000 sq. fl. metal roof.

Greg Petras is the managing partner of Main­tenance Management. Petras point out thatfinding a way to fix the roof wa a major con­cern of his company because million of dol­lars' worth of glass product, including finishedpicture tube, were being stored inside.

"We had some horizol1lal seam leaks as wellas venical eam leaks," Petra explained. "Wewere looking for a recoating system that wouldseal all the leak and, of cour e, eliminate theru ting problems. We looked at several roofingproducts and accepted bids from five manufac­turers. Of the bun h, there were only two thatlooked like they could solve our problems:'

From the pair. Petras' company sell led onASTEC·. a fluid-applied ceramic in ulatingcoating sy tem manufactured by InsulatingCoating' Corporation, Inverness. FL. n influ­encing factor in choosing the system was itslow-priced preparation cos1. Also consideredimponal1l was the product's in ulating propenyand its ability to limit thermal shock. Petrasspeculated that the expan ion and contractionof the original metal roof panels probablycaused the origiml roof' failure.

According to Mel Shaffer of Spa eage Coat­ing, applicator of the A TEC· product. ther­mal shock i usufllly the culprit when melalroofs ru t and/or leak. Themlal shock is expan­sion and contraclion of metal fixture. sheetand fasteners as the metal roof heat and cool .This constant roof movement stresse joil1ls,weaken eams and make. the roof more su ­ceptible to rusl. A contributor to thermal shock,says Shaffer. i metal building insulation thatcau es heat to build-up. With no place to go.heat i retained in the urface. making the rooftemperature even higher.

"Rust i the bi-product of the roofmovement."It generally occurs when thegalvanization wears off metal surface .,Shaffer aid. "A metal heats and cools.the re ulting expansion atld contractioncau e sheet to sl ip and fa teners to100 en, rubbing and elongating holes.Thi rubbing and slipping wears off thegalvanization and allow ru t to formaround fasteners and along trips be­tween sheets." he added. "And ru. t workslike a cancer: it just keeps spreading out.

"That wa the ca e with thi ware­hou e;' Shaffer aid. "The roof of thethree buildings in the complex had a tre­mendou. amount of ru 1. ot only did itcontribute to the leaking problem. bUIsince the roofs were visible from the in­ter tate, they were al 0 a bit of an eye-ore:'

haffer's firm recoated the first build­ing in early Spring. The application tepsincluded power washing and rust re­moval. Atier those steps were atisfac­torily completed, an STEC· primercoat was appl ied, followed by the tinaltop coal. Spaceage Coating i now in theproce of recoating a econd buildingfor MaiJ1lenance Management-a75.800 q. ft. job."

Petra reported that the ICC ceramic

insulating coating are working out fine."We've had everal heavy rains and wind

tonns, and haven't had any problem ."The trength of the IC product is very

imple," haffer aid. ,·It prevel1ls heat fromgetting 10 the urface of the roof. And byprevel1ling heat from reaching the surface.you don't have all the expansion and con­traction thai lead to roofing problems. Thisheat barrier wa demonstrated on another jobwe did. We coated one building withASTEC·, while an adjoining building had arubber mal. The rubber got hot enough toblister skin on contact. At the same lime, theICC roof wa hardly wann. In fact, there wasa 90° difference between roofs."

In addition to metal roofs. ASTEC· canbe u ed on interior and exterior walls. ceil­ings, other sloped roofs. duct , pipes andboilers. It applies with a bru h, roller orsprayer and bond to difficult surface in­cluding galvanized metal, glas '. wood.blocks. cemenl. asphalt and others.

A vinyl terpolymer elastomeric fluidfilled with ceramic panicle, ASTEC· haoutperformed R-20 in ulation in exce siveheat-gain te t . Along with providing an ef­fective heat baITier, the product i fonnulatedto prevent corrosion and re i t UV. chemi­cal, weather and wind damage.