Many of the floors being installed today fail due to improper preparation; in an ever growing competitive environment, contractors are pressured to cut costs to meet project budgets. With the requirement of using specified materials, there is very little that can be done to lower costs in competitive bid situations; most Resinous flooring projects are at least 40% materials. With labor costs on the rise, the difference between winning and losing a bid, is lowering the overall labor costs. Much of the cost of labor is tied up in preparing a floor for installation, therefore that is where many contractors make up time to make their bids more competitive. Owners, General Contractors and Architects need to be aware of this practice before selecting a contractor for a Resinous Flooring project; even though a very low bid is tempting, every bid needs to be qualified.
Many of the issues that cause customers and architects to stop using resinous flooring products are not due to the products themselves; the lack of proper preparation causes as many, if not more failures than hydro-static pressure or bad materials. While the construction market is price driven, it is always important to use contractors that have a reputation for success and service. While it is not always possible to have a perfect installation every time, choosing the correct professional to work with will give you a successful final product. The goal is to get it right the first time, but what separates good from great, is how a contractor deals with adversity.WHY IS PREPARATION SO IMPORTANT?Unlike many other flooring products, finished Resinous products are technically manufactured in place. Ceramic Tile, VCT, and many other sheet flooring goods are manufactured in a controlled environment and installed at your job site; Resinous materials are shipped in parts and manufactured onsite. While this makes installations more challenging, it gives the customer and installer much more freedom for completing necessary details on site without creating seams and awkward transitions. The most important part of the installation process for Resinous Flooring, is the floor preparation. The longevity and overall performance of a Resinous Floor depends on its mechanical and Chemical bond to the sub floor, and this bond can only take place within the porosity of the sub-floor.”Mechanical bonding is a kind of chemical bond that is usually found in rotaxanes and catenanes or other molecular structures that are mechanically interlocked. In this type of adhesive bonding, the adhesive material locks physically onto the surface crevices.” Mechanical/Chemical BondsSimply put, by increasing the profile of a surface and in conjunction with the molecular bonds withing the resin, a chemical and mechanical bond results, creating a bond that is much stronger than the internal bond of the substrate. If a Resinous Floor is installed properly, the internal bond of the substrate should fail before the Resin bond to the substrate. This can be measured quantitatively with a elcometer pull test. ElcometerThere are multiple ways to prepare a substrate for a Resinous floor, but most manufacturers follow standard requirements based on the Resin materials viscosity and specific unique qualities. “A concrete surface profile, known as a CSP, is a standardized measurement for the ‘roughness’ of a surface that is defined by the International Concrete Repair Institute (ICRI). A very rough surface will have a high CSP number, such as CSP 9. A very smooth surface with almost no preparation at all will be a CSP 1.” CSP Reference The ICRI (International Concrete Repair Institute) CSP Chips developed the CSP standard and provides sample chips for evaluating the profile on concrete surfaces. Depending on the thickness of the Resinous system, a CSP profile can be achieved chemically or mechanically by many techniques. In past decades, acids were used to profile the concrete, however due to the difficulty in neutralizing acids and the environmental impact, this practice is rarely done. While every different type of Resinous material has its strengths and weaknesses, their overall performance relies on the bond of the system to the substrate. If proper steps are not taken, a suitable material will fail at the bond line. Without going into great detail, below is a short guide to Resinous floor preparation based on some commonly used system types.Urethane Cements: Most of these types of material are at least 1/8″ thick and many are installed as a mortar exceeding 3/8″. While a CSP 3 is acceptable for most manufactures, a much higher CSP is commonly used (3-5). Along with utilizing shot blasting Blastrac Link or scarifying; key ways must be cut around transitions, terminations, drains and any other breaks in the floor due to material shrinkage during the curing process – not only at the termination but 6″-12″ from the termination.Other Resinous Mortars: Most other mortars are epoxy, but some other systems could include MMA or other resins; Like the Urethane cements, a heavy CSP will add to the quality of the bond, but most other mortars will not need Key lines except at transitions to other materials like metals.Self Leveling Resins (including Flake and Quartz Broadcasts): Many systems that fall into this category are decorative. A CSP 3 is good for SL’s, but any higher CSP can lead to preparation lines telegraphing through the surface. All transitions should always be keyed for any resinous system for strength.Thin Mil Coatings: Most thin mil coatings can be prepared by diamond grinding or “brush blasting” with a shot blaster. A CSP 1-3 is suitable depending on the thickness and manufacture of the materials.NOTE: This is just a simplified guide to preparation, and an installer should always follow the material manufactures recommendations for any system. It is important for the end user and designer to understand the importance of preparation. For a manufactures example please see: Concrete Preparation Guide from Sherwin Williams Summing it up: Because I don’t believe in long reads, I’m going to touch on some other important topics in closing that I will cover in more detail at a later time. None of the above information accounts for slab conditions or other materials that may have been installed previously on the substrate. Preparation is tedious and important to comprehensively understand before installing Resinous products, but if it is done correctly, those products can outlast anything on the market.please feel free to ask questions and leave comments about any other topics that you want covered.
Is OSHA Driving Construction Costs Up?
This article is meant to spark a constructive conversation about the construction safety industry and its affect on construction costs, without ignoring the important safety concerns essential to the construction process. Construction can be a very dangerous endeavor for many trades and the need for regulations and oversight is necessary for job site safety. Even though OSHA is spending more money every year and making more regulations, the overall death toll on construction sites rose from 2011 to 2015. construction-leads-industries-worker-deaths
As a whole, OSHA is a necessary governing body that needs to be in place to protect workers from unsafe practices. They were formed in 1971, but they did not have a major presence on commercial job sites until much more recently. With a rise in knowledge, comes a new perspective on safety and regulations. Since its inception, OSHA has put some very important safety regulations into law and protected many people from dangerous practices. OSHA Timeline While it is important to separate a regulating body from the business it regulates, many of their regulations are not only costly to enforce, but very costly for contractors to comply with. While cost should not be spared for human life, a closer look at the direct costs of each regulation needs to be explored.

In Football, for example, new concussion protocol and new rules have attempted to minimize head injuries in the sport. While high school and college players are not “employees”, their professional counterparts are. With the new knowledge associated with head injuries, kids (and their parents) are turning to different sports with less risk involved. Gifted kids, and those that love the sport, are still playing football in spite of the risk because of the dream of playing professional sports and the pay that comes along with that rare opportunity. The parallel between football and construction is this; there are risks with every career, and more with some than others. Each individual accepts those risks when they join the workforce. It is not possible to have zero risk in any profession, and compensations are based on each jobs risk. This is as true for construction and football as it is for business risk in white collar jobs. The more you risk, the higher possibility for gain and/or failure.

But Why the Lunacy?
Some very important regulations are necessary to keep workers safe, but due to the robotic efficiencies of the 21st century, common sense has been thrown out the window. The MSDS sheets and now SDS sheets are necessary and very helpful, but do not really tell the “whole” story. Many products that we let our kids play with at home require construction workers to wear respirators to handle. Materials are marked with warnings that resemble cigarette cartons. While education is the answer, there needs to be common sense used in creating warnings and regulations. General Contractors are intimidated by OSHA and want to avoid fines, so they make small sub contractors jump through hoops that create chaos and loss in profits. Major General Contractors have created safety positions for job sites and created an adversarial environment where cooperation should be in place. Many safety directors are adversarial, rather than helpful creating a hamper on productivity.
EXAMPLE:
“On a job several years ago, I received a call from the “safety director” (I will leave out GC names and job locations) stating that our crews had been ask to leave the job site because they did not have fit tests for their respirators. I informed him that my men did not need respirators for the work they were doing and the MSDS sheets did not require them; also, they were wearing dust masks, not respirators. He informed me (not so nicely) that my men were wearing respirators (2-strap dust masks with the N-95 stamps are considered respirators) and they could not come back without a fit test. I asked him if I went and purchased cheep low quality dust masks could we continue? He said, Yes. I complained that he was telling me to put my men at greater risk with low quality equipment rather than letting them continue and he said…that’s just the way it is. Later on the same job he made us take a ladder safety class and test even though we had no ladders and were working on the floor.”
My example is extreme, but not that unusual; it shows how regulations that don’t take common sense into consideration can put people at risk and cost time and money. Even though many of the safety directors (even the one in the example above) try to help, they are required to meet exact written perimeters that do not allow for any interpretation. The industry as a whole needs to continue to push safety, but in a more user friendly way. Trade yelling for education; in place of getting kicked off a job, make crews watch relevant training videos in the job site trailer. Creativity has been killed with the advent of rules and regulations run by people who are far away from the actual job site. It is time to think outside the box and create a work environment that seeks to help those who want to comply. It is much less expensive to have a 1/2 day orientation before beginning work, than it is loosing days of work from non-compliance; and less invasive to punish workers with more education rather than sending them home.

The Money:
Safety has become a money making industry but has caused small contractors to loose profits. Many job sites are requiring OSHA 30 trained workers on site for any size company. Some jobs want every person to have an OSHA 10 and first aid. While some contractors are large and need these people on staff for every job, it is a very costly endeavor for small contractors with high employee turnover and seasonal workers. Sub contractors are pressured into low bids on competitive jobs and then required to meet standards that are designed for much larger companies. Many companies bid projects and then discover that they will have to spend hundreds or even thousands per employee to meet tightening requirements for projects. General Contractors and Owners do not know how costly this can be to their bottom line on each project. The industry and its competitive nature is driving prices, but eventually the costs will make it to the overall bottom line on each and every job.
As a whole, OSHA and the new safety regulations are very needed and they serve an important purpose in commercial and industrial construction, but there needs to be a middle qualification and financial help for smaller companies who want to comply, but have found themselves in the dangerous middle ground between profitable work and compliance. When new costly regulation are put into place, low interest loans need to be available to help companies with the costs of compliance. In place of catching workers doing wrong and imposing high fines, why can’t OSHA use its funds for discounted education programs implemented at a reasonable rate for companies to enroll in prior to mobilizing for a job. Why can they not develop in-house training programs for small contractors to implement and manage themselves? I think there are many solutions to this complicated problem that could both save taxpayer money, and protect small business profits. If safety qualifications continue to expand at this rate, the cost of construction will continue to rise and the money that should go to the workers will be forced into compliance. This will be one more program designed to protect the same people that it is harming.
Any thoughts? please post them in the comments section!
