The Jones Avenue Parking Deck in New York consists of seven floors, totaling 140,000 square feet. Working from the top deck down, crews stripped all floors of the existing epoxy waterproof membrane (material unknown), and a new membrane was installed.
After removing the existing membrane, the concrete substrate was sounded. Thirty-pound pneumatic hammers were used to remove any unsound concrete, and patching was applied.
The removal left the surface rough and uneven. Surf Prep Inc. changed the tooling of the cutting drum to better suit the customer's needs, producing a fine profile that in the end, saved the coating company on material costs.
After the initial layer was removed, the milled surface was hit with a Surf Prep carbide scraping machine, the RS-500, to flatten the milled profile. The surface was smoothed further using diamond grinding with HTC Inc.'s HTC-800. Final prep consisted of shot blasting with the Blastrac 2-20D.
Materials used on the project included Sika Lo-Mod 22 epoxy resins and Black Beauty aggregate. The deck was primed, and the epoxy resin was applied at a rate of one gallon per 100 square feet, back-rolled and broadcast with aggregated. After the material set and excess sand was swept from the surface, a second application was completed, followed by the top coating.
The parking deck had to remain open to traffic for the duration of the year-long project. Once the parking stalls were completed, the drive lanes were done, leaving the deck in full operation.
Only a very limited amount of combustible fumes was permitted, so most of the equipment was electric-powered. Ambient dust was not permitted at any time. Surf Prep worked under dust-free conditions using a combination of independent collectors and dust collectors mounted on its equipment.
Jones Avenue Parking Deck
Owner: City of New York, Dept. of Design and Construction
Prep Work: Surf Prep, Pewaukee, Wis.
Resurfacing Work: Rick's Construction, New York