Expert Advice

Identifying and Addressing Common Facility Issues

At Zimcoat, we understand that maintaining a safe and efficient facility requires not only identifying issues but also knowing how to address them effectively. Below, we outline common problems that can arise in various environments, how these issues present themselves, and practical advice on how to remedy them.

Corrosion and Chemical Damage

FACT: Areas exposed to harsh chemicals, such as secondary containment zones or CIP areas, can suffer severe corrosion, leading to concrete degradation and safety risks.

SIGNS:

• Visible pitting, crumbling, or erosion of concrete surfaces.
• Discoloration or peeling of protective coatings.
• Frequent chemical spills or leaks that are not contained.

ADVICE:

• Schedule regular inspections to monitor the condition of these areas.
• Use rapid-setting concrete for quick repairs to minimize downtime.
• Apply chemical-resistant coatings to protect against future corrosion.

Concrete Deterioration and Trip Hazards

FACT: Broken, spalling, or heaved concrete can create serious trip hazards and cause damage to equipment, leading to costly repairs and potential safety violations.

SIGNS:

• Uneven floors, visible cracks, or loose concrete.
• Increased frequency of trips, falls, or damaged equipment like forklifts.
• Complaints from employees about rough or unstable walking surfaces.

ADVICE:

• Mark hazardous areas to prevent accidents until repairs can be made.
• Repair damaged concrete using high-strength repair materials.
• Regularly inspect saw cuts and joints to address early signs of damage.

Moisture and Corrosion in Parking Garages

FACT: Parking garages are vulnerable to water infiltration and de-icing salts, which can cause significant structural damage over time.

SIGNS:

• Cracks or spalling in concrete surfaces.
• Pooled water or damp areas, especially after rainfall.
• Rust stains indicating corrosion of reinforcing steel.

ADVICE:

• Apply waterproofing membranes to prevent water penetration and freeze-thaw damage.
• Use sealants that resist de-icing chemicals to protect against corrosion.
• Regularly inspect and repair expansion joints to prevent further deterioration.

Maintaining Hygiene and Safety in Food Processing Areas

FACT: Floors in food processing areas must meet strict hygiene standards and resist corrosive substances like animal waste and cleaning chemicals.

SIGNS:

• Frequent buildup of grime and difficulty cleaning floors.
• Corrosion or pitting in areas exposed to chemicals or by-products.
• Visible wear in high-traffic areas such as production lines.

ADVICE:

• Use CFIA-approved coatings that are easy to clean and resist bacteria.
• Regularly inspect and reapply chemical-resistant coatings to prevent corrosion.
• Consider seamless, non-porous flooring solutions that resist contamination.

Handling Moisture and Traffic in Livestock Environments

FACT: Dairy barns and other livestock environments are exposed to constant moisture and animal by-products, which can quickly degrade flooring and create unsafe conditions.

SIGNS:

• Wet, slippery surfaces that are difficult to clean.
• Visible damage from heavy livestock traffic.
• Odor or discoloration of flooring materials.

ADVICE:

• Install moisture-resistant coatings that can withstand constant wet conditions.
• Use textured, slip-resistant surfaces to prevent falls.
• Schedule regular maintenance to address wear and tear from livestock.

Tank Linings and Containment Integrity

FACT: Tank linings must resist chemicals, high temperatures, and pressure to prevent leaks and contamination in industrial storage.

SIGNS:

• Discoloration, blistering, or peeling of the tank lining.
• Frequent leaks or signs of corrosion on tank surfaces.
• Variations in the stored substance’s quality or safety.

ADVICE:

• Inspect tank linings regularly for signs of wear and corrosion.
• Use chemically resistant linings appropriate for the stored substance.
• Schedule timely reapplication of linings to prevent costly leaks and contamination.

Ensuring Safety in Sensitive Electronic Environments

FACT: In environments where sensitive electronics are used, controlling electrostatic discharge is crucial to prevent equipment damage and safety hazards.

SIGNS:

• Frequent equipment malfunctions or damage due to static discharge.
• Difficulty maintaining stable environmental conditions for sensitive operations.
• Complaints of static shocks from personnel.

ADVICE:

• Install ESD flooring and grounding systems to dissipate static charges.
• Regularly test and maintain ESD controls to ensure effectiveness.
• Educate staff on best practices for minimizing static buildup.

Structural Movement and Sealant Integrity

FACT: Expansion joints and sealants are essential for accommodating structural movement and preventing water infiltration in various construction projects.

SIGNS:

• Cracked or damaged expansion joints, leading to structural stress.
• Water seepage through joints, causing underlying damage.
• Visible deterioration of sealants, resulting in gaps or leaks.

ADVICE:

• Regularly inspect and replace worn or damaged expansion joints.
• Use high-quality sealants designed for the specific environmental conditions.
• Apply protective coatings over joints to extend their lifespan.

Protecting and Maintaining Industrial Surfaces

FACT: The right epoxy and coating systems are critical for protecting surfaces in industrial environments, ensuring durability and resistance to chemicals and wear.

SIGNS:

• Surface wear, including scratches, chips, or fading.
• Chemical stains or signs of corrosion on coated surfaces.
• Slippery conditions, especially in wet or oily environments.

ADVICE:

• Choose epoxy systems for areas requiring high durability and chemical resistance.
• Use polyurethane coatings for flexible, UV-resistant protection.
• Regularly maintain and reapply coatings to ensure continuous protection.

Glossary of Industry Terms

• Antimicrobial Coatings: Coatings designed to inhibit the growth of bacteria, mold, and other harmful microbes, commonly used in medical and food processing environments.
• CIP (Clean-In-Place): A method for cleaning the interior surfaces of equipment without disassembly.
• Chemical-Resistant Coatings: Protective coatings designed to withstand exposure to harsh chemicals, preventing corrosion and damage.
• Deck Sealants: Waterproof coatings applied to surfaces like parking decks to protect against moisture, salts, and chemicals.
• Epoxy: A durable, chemical-resistant resin used for coatings and adhesives, known for strong adhesion and protection.
• ESC (Electrostatic Control): Systems and practices to prevent electrostatic discharge, especially in sensitive environments.
• ESD (Electrostatic Discharge): The sudden flow of electricity between two electrically charged objects, which can damage electronics.
• Expansion Joints: Gaps placed in concrete or other materials to allow for expansion and contraction, preventing cracks.
• Moisture-Resistant Coatings: Coatings that prevent water penetration, protecting surfaces from damage caused by moisture.
• Polyurethane: A flexible coating that provides UV resistance and is ideal for surfaces exposed to outdoor environments.
• Rapid-Setting Concrete: A type of concrete that cures quickly, ideal for fast repairs in critical areas.
• Secondary Containment: Structures designed to prevent chemical spills from reaching the environment, often involving chemical-resistant materials.
• Slip Resistance: Surface treatments or coatings designed to reduce the risk of slips and falls.
• Spalling: The flaking or breaking of concrete, usually due to moisture, freeze-thaw cycles, or physical stress.
• Static Control Flooring: Flooring systems designed to dissipate static electricity, crucial in environments with sensitive electronic equipment.
• 5S: A workplace organization method emphasizing Sort, Set in order, Shine, Standardize, and Sustain.
• CFIA (Canadian Food Inspection Agency): Regulatory agency enforcing food safety, animal health, and plant protection standards in Canada.

How Can Zimcoat Help You?

Whether you’re dealing with sector-specific issues or planning ahead for future projects, Zimcoat is here to provide the expertise you need. Recognizing the signs of potential problems and understanding the terminology are the first steps to maintaining a safe, efficient, and compliant facility. Contact us today at [email protected] or call 905.450.2989 to discuss how we can support your project.