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Featured Projects: Problem Solving
Project #101 | Taber Hill Winery & Restaurant, Buchanan, MI
PROBLEM
A 20 year old, 5500 sq. ft. roof over a wine making operation was leaking. Restaurant with a concrete deck on the roof area was unsightly and weather damaged. In addition, the 2 x 12 ft. wooden facia and parts of the wooden rail system were experiencing rot and as a result required continual maintenance (painting). Numerous attempts to seal the many cracks and waterproof with liquid coatings were unsuccessful.
SOLUTION
Duradek ULTRA (60 mil vinyl). Damaged surface was repaired using an acrylic modified concrete topping mix. Rails were then removed and rotted 2 x 12 foot facia were replaced. PVC coated metal was used on the perimeter to completely cover and protect the facia. The Duradek Ultra was then installed and welded to PVC flashings. To complete the maintenance free system, the wood rails were replaced with powder coated (PVC) aluminum rails.
For complete details, please see Case History 101 (1.4 Mb PDF file).
Project #102 | Cavanaugh's Inn at the Park, Spokane, WA
PROBLEM
A three-terrace concrete deck over the kitchen and dining areas had been leaking for years. Numerous asphaltic patching attempts had not solved the problems. Artificial turf overtop compounded problems by keeping moisture on the surface. Severe ponding problems existed in the corners.
SOLUTION
Duradek Solution: Duradek ULTRA (60 mil) Taupe. Perimeters were secured with "L" trim (used as a gum stop) and caulked with urethane sealant. Low areas were leveled with an acrylic modified topping mix to eliminate the puddling problem. A total of 3,500 sq.ft. of Duradek Ultra was applied to the entire area.
For complete details, please see Case History 102 (1.7 Mb PDF file).
Project #103 | Avoca Apartments, Toronto, Ontario
PROBLEM
Two, twenty-story apartment buildings were experiencing serious leakage problems on balconies due to cracked concrete. The artificial turf on most of the balconies trapped moisture and contributed to delamination of the sloped concrete topping. Not only was water entering the suites, but further serious damage due to the freeze-thaw cycle would inevitably require major reconstruction work if the areas were not completely waterproofed.
SOLUTION
Duradek Supreme (25 mil) Taupe. To determine the costs and problems for this project, a test phase of 20 balconies (between 200-550 sq.ft. ea.) was completed in year one. All the glued-down carpet was removed and disposed of. Many of the balconies had delaminated concrete, which was broken up with kango guns and removed at the rate of 14 cu.yds. per day. Often working on a swing stage from outside the building, new drain holes were drilled through the concrete walls. The surface was trowelled with an acrylic modified topping mix to provide smooth finish to accept the vinyl. After the Duradek was glued down, the perimeters were secured with "L" trim, used as a gum stop, and sealed with urethane.
For complete details, please see Case History 103 (1.5 Mb PDF file).
Project #104 | Oak Lane Apartments, Dallas, TX
PROBLEM
In the spring of 1982, the Duradek applicating contractor had repaired 30,000 so. ft. of balconies, walkways and stairs of a thirteen building apartment project. There was massive sub-structure damage due to water leakage through the lightweight concrete decking. Over 50% of the total area was rotten, creating a serious safety hazard.
SOLUTION
Duradek Classic (20 mil). After major repairs were done to the rotten substructure, the contractor waterproofed the original 30,000 sq.ft. project with Duradek. When called in years later, the contractor easily repaired the small tears, replaced the worn landings and pressure-washed the entire surface to bring back the appearance and non-skid texture (hidden under dirt).
For complete details, please see Case History 104 (1.1 Mb PDF file).
Project #105 | Waterford on South Hill, Spokane, WA
PROBLEM
As a new apartment complex under construction, they needed material that would double as roofing and decking over their kitchens. They also needed 110 outdoor decks covered with a maintenance-free product.
SOLUTION
Duradek Custom Wedgewood (20 mil), Duradek ULTRA Steel (60 mil). The balconies were covered with Duradek Custom, as the six foot wide vinyl material required no se
For complete details, please see Case History 105 (1.3 Mb PDF file).
Project #106 | Mel Tillis Theater Branson Inn, Branson, MO
PROBLEM
A newly constructed four-storey addition to the existing Inn had already experienced leaks on the outer edges of the hollow core balcony slabs where the concrete slabs had many cracks. Previous attempts to waterproof the surface with liquid sealants proved unsuccessful. The owners were concerned about the long term effects of water penetration on the concrete and metal structure as well as the appearance.
SOLUTION
Duradek ULTRA Steel (60 mil). Surface cracks were filled with a polymer grout. The concrete was broom finished and needed grinding to smooth it down. The vinyl was applied with a contact type adhesive. The perimeters were secured with "L" trim to both the steel fascia and the brick wall.
For complete details, please see Case History 106 (1.2 Mb PDF file).
Project #107 | Northwest Community College, Terrace, British Columbia
PROBLEM
Ceramic tile floors in showers, sink and toilet areas were leaking into and through the ceilings below. The maintenance staff of the college had tried other methods of waterproofing the grout lines, but with no lasting success.
SOLUTION
Duradek Supreme (25 mil) Different Colours. Duradek was glued with contact type adhesive directly over the ceramic tiles with no prep work whatsoever. The grout lines were very thin and did not telegraph through the vinyl. The perimeters of the toilet and change areas were secured with "L" trim used as the gum stop and sealed with urethane caulking. In the showers, the Duradek membrane was run up the walls 8 inches and lapped with a shower wall panel. The vinyl was "seated" into a urethane sealant around the existing shower drains.
For complete details, please see Case History 107 (1.3 Mb PDF file).
Project #108 | Grand Okanagan Hotel, Kelowna, British Columbia
PROBLEM
A newly constructed luxury hotel on the lakeshore needed an attractive, durable, long- lasting waterproof membrane on all the balconies and stairs. The underside of these structures was finished with an acrylic stucco so it was necessary to completely waterproof the top surface.
SOLUTION
Duradek Ivory Custom (20 mil) was glued to T. & G. plywood and secured on the perimeters with mini-trim. The plywood staircases were covered on both riser and runner with a continuous vinyl sheet. Stair nosings were installed to protect the leading edge from abuse and excessive abrasion.
For complete details, please see Case History 108 (1.8 Mb PDF file).
Project #109 | Bonnieview Country Club, Baltimore, Maryland
PROBLEM
A 3800 sq. ft. concrete patio over a breezeway and men's locker room was leaking. Approximately half the slab was removed and replaced and the other half (which was in fair shape) was covered with indoor/outdoor carpeting. After five years, the concrete had some fractures and was starting to leak again. The Country Club had spent many thousands of dollars restoring the concrete the first time and now were faced with a proposal for sixty thousand dollars to do it again.
SOLUTION
Duradek Surcoseal 60. The indoor/outdoor carpeting was removed and the entire surface was patched with an acrylic modified leveller. The aluminum rails were removed and stored off to the side. Duradek vinyl was installed with the outside perimeter finished in galvanized drip edge with Duradek PVC clip system. The actual vinyl installation took only two days and was useable immediately. The entire job was installed for about one third of the cost of the concrete restoration proposal. A five year waterproofing warranty was given with the installation, even considering that the surface would have occasional golf spike traffic.
For complete details, please see Case History 109 (1.6 Mb PDF file).
Project #110 | Kingston Apartment Complex and Parking Garage, Ontario
PROBLEM
This 35 year old apartment complex had an underground parking garage that was leaking. The original waterproofing was a "between-slab" roofing membrane which had failed. Tenants were forced to build tarp structures over their vehicles to protect them from dripping water. Steel structural materials were at risk because of all the water. The deck surface over the garage, which many of the tenants looked onto, was an eyesore.
SOLUTION
Duradek Commercial. Original surface was ground down, then levelled off with an acrylic modified cement. Duradek was then applied over the entire surface and 6 inches up the wall, where it was mechanically terminated. The outside perimeters were turned over 6 inches as well, which was enough to cover the entire exposed edge of the concrete slab.
For complete details, please see Case History 110 (1.6 Mb PDF file).
Project #111 | Maui Parkshore Apartments
PROBLEM
Concrete walkways on the second and third floors had never been waterproofed. There was hairline fractures throughout the walkway surfaces, the concrete was spalling and sections of the fascia had broken away. A consulting engineer had been hired and he recommended that the prime fractures be routered out and injected with epoxy. The concrete restoration part of this project cost in excess of 890.000. These are rented condos, so it was important to find a solution where the entire facility could continue to be rented during the waterproofing process.
SOLUTION
Duradek ULTRA was installed on all the walkways. The vinyl was finished at the junction of the concrete deck and stucco wall with Duradek's approved urethane sealant detail. The vinyl was extended over the edge and mechanically fastened with Duradek's aluminum trim system. Because Duradek vinyl moves independently and can bridge surface gaps, much of the costly epoxy injection was unnecessary.
For complete details, please see Case History 111 (1.6 Mb PDF file).
Project #113 | Menehune Shores, Maui
PROBLEM
Duradek solved a tricky waterproofing problem on this large roof terrace deck of a six storey concrete condominium in Kihei, Maui. The deck is just under 16,000 sq/ft and is used daily by the patrons to BBQ their dinners and enjoy the beautiful Hawaiian sunset.
Due to the high temperature roof environment, movement in the topping slab had resulted in frequent leaks into the 6th floor units and trapped moisture between the coatings, topping slab and structural planks. Previous coatings had failed and would be cumbersome to replace. Complete removal of the existing roof membrane would be too risky if it were to rain, not to mention the additional cost that it would incur.
SOLUTION
To rectify the problem, large areas of failed coatings were scraped up and the deck was sanded with deck sanders and primed.
After these repairs were made, Duradek (a single-ply, waterproof, walkable vinyl membrane) was chosen to be applied right over top, making it watertight and attractive at the same time. When the material was to be ordered, the colors Duradek Ultra Heritage Sienna and Duradek Ultra Surcoseal Suede were chosen. These products were installed in a “window- pane” pattern, using Suede for the frame and Sienna for the fields.
Project #114 | Harbour Side Residence, Vancouver
PROBLEM
This job came to us through Shell Busey, the creator of the HouseSmart Home Services Referral Network and home improvement expert. The customer and he worked together in broadcasting and he found out she was going to tile her outdoor decks. Tens of thousands of dollars had been spent having the deck rebuilt and waterproofed in preparation for a tile surface. However there was minimal slope, poor drain details and inadequate perimeter detailing. The waterproofing was a granular surfaced torch-applied roof system, similar to shingles (no approvals, no warranty if tile applied over top). This job, as originally planned, was a guaranteed failure!
SOLUTION
The deck was re-sloped and HardiBacker® was used as the final surface for the Tiledek to be applied to. The detailing on the perimeters was all done with appropriate roofing details and the appropriate tile was purchased to handle the Vancouver climate. A tile professional, who had much experience with outdoor tile, was hired to do the job. He used top quality Mapei thinsets and grouts. Duradek Ultra Tiledek was the perfect solution to waterproof the structure and provide a method of holding the tile firmly to the substrate.