CONTINUING EDUCATION

INNOVATIVE MATERIALS HELP ENERGY Presented by: INNOVATION CENTER EARN LEED PLATINUM CERTIFICATION AND HISTORIC TAX CREDITS

THE CONNELLEY LEGACY CONTINUES The Clifford B. Connelley Technical Institute opened in 1931 as a Depression-era workforce development facility where students learned essential trades such as plumbing, carpentry, and mechanics. Connelly educated generations of skilled tradespeople and workers from and the surrounding region but closed in 2005 after years of declining enrollment. Many educators and city leaders continued to advocate for a renewed investment in vocational education, particularly at a time when labor shortages in the construction industry were at an all-time high. In addition, sustainable design is on the rise, so the industry needs skilled laborers familiar with these innovative green materials and technologies. Mayor called for a “Pittsburgh Connelley for the 21st century,” and today their vision has materialized in the new Energy Innovation Center (EIC).3

HISTORICAL FACTS ABOUT THE SITE AND ARCHITECTURE4

• The school is located in the Hill District neighborhood of Pittsburgh, a historically African-American cultural and business hub • The school was sited high on a hill so it could remain above the air pollution that plagued Pittsburgh • The architect, Edward B. Lee, was known for his work on academic buildings • The original main entrance is flanked by symmetrical academic wings, a characteristic of its Classical Revival architectural style • The shop building was designed to mimic an actual 1930s factory, and its unique saw-tooth roof was designed to maximize natural interior light • Students at the Connelley School learned plastering, bricklaying, plumbing, auto LEARNING OBJECTIVES mechanics, carpentry, cabinetry, electrical, agriculture, commercial arts, home economics, cosmetology, and nursing, among other skills Upon completion of this course the student will be able to: 1. Explore the history of the Energy Innovation Center—Pittsburgh project and how LEED Platinum Certification and Historic Tax Credits were achieved simultaneously. 2. Review how closed-cell spray polyurethane foam (SPF) insulation met wall assembly challenges. 3. Explore how polyiso board insulation met roofing design challenges at the Energy Innovation Center. 4. Describe how two-component waterborne polyurethane coatings were used on both concrete and wood floorings, as well as for an innovative wall coating.

CONTINUING EDUCATION

AIA CREDIT: 1 LU/ELECTIVE AIA COURSE NUMBER: AR052019-1 Use the learning objectives above to focus your study as you read this article. To earn credit and obtain a certificate of completion, visithttp://go.hw.net/AR052019-1 and complete the quiz for free as you read this article. If you are new to Hanley Wood The Clifford B. Connelley Technical Institute opened in 1931 as a Depression-era workforce development University, create a free learner account; returning users log in as usual. facility where students learned essential trades such as plumbing, carpentry, and mechanics. CONTINUING EDUCATION

THE ENERGY INNOVATION CENTER GLOSSARY Under the leadership of Pittsburgh Gateways Spray polyurethane foam insulation Corporation, and with the help of non-profits, A spray-applied cellular plastic made by mixing unions, foundations, research universities, chemicals that react very quickly, expanding on the U.S. DOE’s National Energy Technology contact to create foam that insulates, air seals, and provides a moisture barrier.1 Laboratory, and industry partners, the historic school has been transformed into a 200,000 Polyiso board insulation A closed-cell, rigid foam board insulation consisting square foot, LEED Platinum multi-disciplinary of a foam core sandwiched between two facers. campus. The Energy Innovation Center is a The facers are composed of various organic and not-for-profit organization with a mission to inorganic materials, usually paper and fiberglass. It engage corporate and community leaders, align is widely used in residential and commercial markets workforce development and education, develop for both roof and side wall applications.2 and demonstrate technology, and incubate Aromatic hardener businesses to support emerging clean and A reactive component of a two component coating sustainable energy markets.5 system with an amber to brown color. An aromatic hardener reacts with the resin side to produce a This 6.6 acre, urban commercial complex is coating film that is not light stable and will yellow The Energy Innovation Center is a leader in green adaptive reuse, as a collaborative hub that promotes energy- over time when exposed to sunlight or ambient the design of its building and grounds meets the highest standards light sources. sector research and innovation and creates of sustainability and energy efficiency while preserving the historical direct and deliberate bridges to job creation, character of the building. Aliphatic hardener A reactive component of a two component coating entrepreneurship, and urban economic sustainable footprint. Drawing on the Connelley system that is water-clear. An aliphatic hardener revitalization to support the Pittsburgh reacts with the resin side to produce a coating film 6 legacy, the new Energy Innovation Center is region’s emerging clean technologies. EIC is that is very light stable and will not yellow over time connecting sustainable careers aligned with the located in the heart of Pittsburgh’s Historic when exposed to sunlight or ambient light sources. region’s changing economy. Lower Hill District, a neighborhood located Solventborne (SB) carrier between several major research university SIMULTANEOUS GOALS OF LEED PLATINUM Coating where the primary co-solvent is an organic campuses and the downtown central business CERTIFICATION AND HISTORIC TAX CREDITS solvent which may or may not be classified as a VOC. district. This building serves as a ‘living Waterborne (WB) carrier laboratory' for industry education and training, The energy technology innovation cluster Coating where the primary co-solvent is water, accommodating hundreds of students in 28 in the Pittsburgh region has a rich history although it may still contain a small amount of apprentice programs. The EIC also houses and a promising future. World-class capacity organic solvent which may or may not be a VOC. diverse tenants, including a national research exists here in areas ranging from carbon Polyurethane dispersion (PUD) Typically contains a polymer dispersion laboratory, energy sector corporations, political management to nuclear reactor design, wind turbine manufacturing, materials and sensors, primarily composed of a polyester, polyether, or and community leaders, numerous nonprofits polycaprolactone resin pre-reacted with an aliphatic electric power distribution and control, shale and businesses, a co-working space, design hardener and dispersed in an aqueous carrier. lab, and five Pittsburgh universities.7 The gas production, and advanced building Additional additives may include pigments, flow and 8 basement alone will house a 9,500-square-foot systems. The Energy Innovation Center is a leveling additives, and/or defoaming agents. Community Kitchen facility to engineer new leader in green adaptive reuse, as the design One-component (1K) coating ways to make high volumes of food using fewer of its building and grounds meets the highest Ready to use out of the can, moisture cure (MC) or chemicals, electricity, paper, and gas. standards of sustainability and energy efficiency polyurethane dispersion (PUD). while preserving the historical character of Two-component (2K) coating Energy Innovation Center—Pittsburgh is the building. Through an integrated design- Contains a formulated resin component and a designed and equipped by corporate partners build process, EIC designers and engineers hardener component. such as building material manufacturers, lighting innovated to optimize the performance of Rehabilitation manufacturers, and a power company. High-tech vendor components. The EIC has earned LEED The process of returning a property to a state building materials can be found throughout the Platinum certification and meets the stringent of utility, through repair or alteration, which makes possible an efficient contemporary use facility, showcasing chemistry as a sustainable 2013 District energy, water, and transportation while preserving those portions and features of solution and helping the EIC maintain its 9 emissions reduction targets. the property which are significant to its historic, architectural, and cultural values. RENOVATION CHALLENGES In addition, the building is listed on the National Register of Historic Places and is a Secretary of the Interior’s Standards for The Energy Center is an 85-year old education Pittsburgh History and Landmarks Foundation Rehabilitation facility, providing three renovation challenges: Used to determine if rehabilitation of a historic Historic Landmark, making it one of the • The building had little or no insulation property qualifies as a Certified Rehabilitation only LEED Platinum designed structures to for Federal tax purposes. The Standards intend to • The renovation had historical landmark qualify for Historic Tax Credits in the nation. assist the long-term preservation of a property's requirements According to architects DLA+, “The decision significance through the preservation of historic • The renovation needed to meet LEED materials and features. platinum standards to adaptively reuse and renovate the historic Connelley Pittsburgh’s Hill District to save CONTINUING EDUCATION

a part of Pittsburgh’s heritage was no easy Tax Credit program.11 This unique combination vision. Its Trade School in landmark status, the of historic preservation and highly sustainable obsolete mechanical systems, and a building architecture has proven very successful. that was practically inaccessible according to today's ADA standards were only a few of the EIC AND SUSTAINABILITY PARTNERS hurdles. However, the greatest challenge lay Buildings are responsible for 40 percent in the simultaneous goals of LEED Platinum of global energy consumption and about certification and historic tax credits. A year-long one-third of the greenhouse gases emitted process of negotiations and design reviews with to our atmosphere. However, a lot can be the Pennsylvania State Historic Preservation done to make buildings more environmentally Office and the (NPS) compatible. Through their partnership, the EIC ensued. Time and again, innovative green worked with building product manufacturers design had to be balanced against the directive to educate about the ways buildings can to preserve character-defining features of the be designed sustainably and operated more historic school building while also meeting the efficiently. Today, buildings must consume less competing goals of the client.” energy and emit lower amounts of greenhouse Many historic structures such as the Connelley gases. They must be durable and efficient, and School were designed with inherent energy- meet the demands for comfort and design. saving qualities including operable windows, Choosing innovative and appropriate materials ample natural light sources, clerestory windows and solutions helps improve the performance of 12 and skylights, wide, overhanging eaves, or buildings and the quality of people's lives. heavy masonry walls. Due to these features, Efficiency in building is not just a matter of historic preservation, energy efficiency, and having the right parts; it also depends on how An application area of 56,000 square feet of closed-cell SPF was environmental sensitivity are not mutually you assemble the whole. At the EIC, the design- installed throughout the EIC to ensure continuous insulation that 10 exclusive, as was proven at EIC. Now, the build team followed efficiency principles to helps eliminate thermal breaks and seals the building envelope to optimize insulation value. facility has achieved LEED Platinum rating and optimize the performance of the whole system: has the potential to be one of the highest • Data collection and transfer rated LEED Core and Shell projects ever. The state-of-the-art equipment, and got tangible EIC design team met the Secretary of the • Continuous commissioning results in that effort,” explains Bill Miller, CEO of the EIC. Interior’s Standards for Rehabilitation, and the • Measurement and verification Owner was awarded a 20% tax credit of $6.5 • Heating and cooling13 SPRAY POLYURETHANE FOAM PROVES Million through the Rehabilitation Investment TO BE AN ECONOMICAL INVESTMENT16 There were, of course, myriad building materials used in the renovation of the EIC building, but It may seem preposterous today, but when the this course will discuss two uses of polyurethane Connelley Technical Institute was built insulation insulation and two types of architectural was not incorporated into the construction. coatings that were employed to improve energy When renovations began in 2011, adding efficiency, provide durable surfaces, and meet high-quality insulation to the building's exterior historic preservation standards. was mandatory to meet the building's energy efficiency goals (and provide occupant comfort POLYURETHANE INSULATION— through Pittsburgh’s cold winters and hot MULTI-PURPOSE INSULATION CHOICE summers). After examining several types of insulation, the project team chose closed-cell Highly insulative polyurethane foam was used spray polyurethane foam due to its several throughout the roof and walls of the EIC during unique benefits. Closed-cell SPF has nonintrusive its renovation to help improve the performance of versatility, high R-Value, moisture resistance, adds the facility’s building envelope. Closed-cell spray structural strength, and provides a drainage plan polyurethane foam (SPF) was used in the wall when installed as continuous insulation. systems, providing continuous insulation to create an airtight seal and eliminate thermal breaks.14 “Historic buildings generally have greater potential Polyiso board insulation was used for the EIC for air leakage, and traditional insulation methods roofing system, which allowed for a cost-effective, do not combat this,” says Joe Morrone, the EIC high-performance roof system. It features project manager with InsulRight, the company environmentally-friendly construction with zero that installed the spray foam at the Center. ozone-depleting components and is CFC-free.15 “Buildings perform as a system and insulation plays a big role in that system. Maintaining the Through their partnership, the EIC worked with building product “We used a well-thought-out approach to air movement throughout a building helps all the manufacturers to educate about the ways buildings can be designed improve the efficiency of the shell and installed sustainably and operated more efficiently. mechanicals perform as designed.” CONTINUING EDUCATION

While there are multiple choices of spray QUIZ polyurethane foam insulation available, specifiers often choose closed-cell SPF for exterior 1. The Energy Innovation Center received historic tax credits and LEED ______Certification. applications since it creates a continuous layer of a. Silver b. Gold highly water-resistant insulation. An application c. Platinum area of 56,000 square feet of closed-cell SPF was installed throughout the EIC to ensure 2. ______was used in the wall systems at EIC, providing continuous insulation to create an airtight seal continuous insulation that helps eliminate and eliminate thermal breaks. thermal breaks and seals the building envelope a. Polyiso board insulation b. Spray polyurethane foam to optimize insulation value. With closed-cell SPF, c. Mineral wool d. Fiberglass insulation the building did not need an additional building 3. ______was used for the EIC roofing system, which allowed for a cost-effective, high-performance roof system. wrap as a drainage plane, which cut back on a. Polyiso board insulation b. Spray polyurethane foam renovation time and resources. c. Mineral wool d. Fiberglass insulation Additionally, closed-cell SPF products can offer a low installation cost and design flexibility, 4. Spray polyurethane foam helped the Energy Innovation Center achieve a ______percent savings in their gas utilities. helping to create a durable and efficient thermal a. 42 b. 56 envelope. It is installed using a chemical blowing c. 68 d. 74 agent that is retained inside the polymer cells 5. Polyiso board is a ______product, which means that it will not change shape or melt when exposed to to form a rigid, dense foam. This rigidity and elevated temperature. density provides an enhanced air barrier, limits a. Thermoset b. Thermoplastic moisture ingress, and can add structural integrity c. Thermoformed to a building’s exterior. SPF can be used to insulate much more than just walls, providing 6. ______hardeners are more color stable, so the polymer does not break down and yellow over time. insulation, sealing, and strength for ceilings, a. Aromatic b. Aliphatic floors, attics, foundations, and piping. c. Resin d. High-performance

“The old masonry walls of the building and 7. ______is an entanglement and reaction of polymer chains that increases physical strength and chemical resistance. vapor retarding properties of closed cell spray a. Hydrogen bonding b. Crosslinking polyurethane foam were major driving forces c. Dispersion behind the decision to use [closed-cell SPF] for this project,” Morrone says. “Framing sizes 8. Properties of 2K waterborne coatings include which of the following? also came into play. The high R-Value per inch a. Excellent durability b. Excellent color of closed cell allowed the contractor to reduce c. Excellent gloss d. All of the above the framing size and still achieve the desired thermal performance in the building envelope.” 9. 80 percent or more of coating or sealer failures are due to ______. a. Poor surface preparation b. Application issues Spray polyurethane foam provides additional value c. Wrong coating by helping to minimize heating and cooling bills over time and serves as a moisture and air barrier, 10. A ______was used to coat an original 5/4" maple wood floor that was installed in what used to be which can eliminate the need to install separate a machine shop training room. air or moisture management systems. In some a. 100% solids epoxy basecoat b. 2K waterborne polyurethane topcoat situations, the use of closed-cell SPF alone can c. 2K waterborne polyurethane clear coat reduce fuel bills. And at the EIC, the installation of this insulation, thermal windows, updated climate systems, and low-energy appliances and lighting have already resulted in significant utility SPONSOR INFORMATION bill savings. “We were able to cut energy usage in half,” Miller says. “Our energy model predicted a 57 percent reduction in energy from our baseline and our numbers [actuals] are coming in pretty close to that. The building had no insulation, and everything was from the 1930s, so our baseline model was pretty bad.” As an innovation leader in the development of high performance coating and sealant raw material technologies, Covestro, LLC enables architects, designers and building owners by providing real world solutions for built This article continues on environment challenges. Covestro, LLC develops coating and sealant solutions for flooring, interior and exterior http://go.hw.net/AR052019-1. Ä walls and trim, and roofing and waterproofing with high performance and sustainability in mind. Go online to read the rest of the article and complete the corresponding quiz for credit. CONTINUING EDUCATION

In addition, the use of closed-cell SPF helped POLYISO BOARD INSULATION IS A the center qualify for historic tax credits. It was COST-EFFECTIVE ROOFING INNOVATION17 not necessary to change the historical integrity Polyiso Board insulation is the dominant of the interiors since closed-cell SPF could be solution for low slope roofing. Polyiso allows added into the existing wall dimensions without for the most cost-effective roofing assembly the need to increase wall thickness. “By using a and requires fewer components to achieve closed-cell high-density foam, we were able to equal or better performance than other achieve the same R-Value in half the distance, roofing assemblies. Polyiso board provides using three-and-a-half-inch studs, and receive more insulating power per inch than the other the tax credit,” Miller explains. common types of foam insulation board, As a result of the spray foam insulation meaning you can use less material while still products used in the EIC's renovation, the meeting code. community will now enjoy a robust and Polyiso board is not only intended for roof resilient building that not only operates with applications, but can also be used on walls, lower energy consumption but also serves as and even below grade. Polyiso boards always an example for how products like closed-cell contain facer materials on both sides of the SPF can play an energy-efficient role in historic board. The facer can be chosen to impart preservation projects. Spray polyurethane foam additional functionality to the board, such helped the Energy Innovation Center achieve a as water-resistance, air resistance, and fire 68% savings in their gas utilities. resistance. Polyiso helps reduce a building’s carbon footprint, as it features environmentally friendly construction with zero ozone depleting “Our top priority was energy components and is CFC free. Architectural coatings used at the EIC include a two-component waterborne polyurethane topcoat for concrete floors, a similar efficiency, and the LEED The 43,500 square foot roofing system at topcoat formulated for oil-stained maple floors, and a ‘dry the Energy Innovation Center features 4-inch erase paint’ coating also based on two-component waterborne certification came along with it,” polyurethane technology. tapered polyiso and a thermoplastic polyolefin states Miller. “We weren't sure (TPO) roofing membrane. Roofing assemblies materials, which allows for the thinnest where we were going to end up, that feature polyiso as the insulation have high roof profile with fewer layers. To achieve but we made sound decisions compressive strength, which allows access to an insulation value of R20 on the roof deck roofs without causing damage and provides required 3 inches of polyiso board. To achieve based on energy efficiency. We resistance to hail and other projectiles. Polyiso the same value with extruded polystyrene foam don't have any technologies that is a thermoset polymer that will not melt or boar would require 4 inches, or with expanded deform under the high temperatures typically polystyrene foam board, 5 inches. are proprietary in the building, encountered on a roof deck. Polyiso board and we want to show that others is lightweight, cuts easily with a knife, and is ARCHITECTURAL COATINGS attached to the roof deck either with screws or can purchase off-the-shelf items adhesive so is very easy to install. A two-component waterborne polyurethane topcoat based on high-performance resins and get positive results.” Polyiso has the highest R-value (insulation protects against long term wear and stains on property) per inch among common insulation the EIC’s 86 year old concrete floors and in the Bright Space Room where oil-stained maple floors were brought back to life. In addition, two rooms in the building received a ‘dry erase paint’ coating based on two-component waterborne polyurethane technology. The coating allows the room occupants to write anywhere on one of the walls in the room in lieu of a dry erase board.

HISTORY AND SCIENCE OF TWO- COMPONENT (2K) WATERBORNE POLYURETHANE TOPCOAT The product used was a two-component waterborne polyurethane satin resin. This water-based, breathable, aliphatic urethane The 43,500 square foot roofing system at the Energy Innovation Center features 4-inch tapered polyiso and a thermoplastic polyolefin (TPO) roofing membrane. is available in low or high gloss sheen, clear, CONTINUING EDUCATION

TIMELINE OF HIGH PERFORMANCE The 1970s also saw the advent of 2K solvent- HYDROGEN BONDING AND CROSSLINKING COATING DEVELOPMENT borne polyurethanes. The two-component = HIGH PERFORMANCE material is a resin blend with additives, such 1930s Urethanes developed by Otto Bayer There are two fundamental reasons that as leveling aids, catalysts, solvents, pigments, polyurethane coatings have such high 1940s Aromatic hardeners used in coatings and extender pigments reacted with either performance: hydrogen bonding and an aromatic or aliphatic hardener. The early cross-linking. The polyurethane segments in 1960s Development of aliphatic hardeners resins used in these systems, typically poly- for coatings the polymer chains act like small magnets ester resins, had a very high viscosity. It was with a positive and negative end. Hydrogen 1970s Waterborne (WB) polyurethane necessary to add solvents to create a coating bonding occurs when billions of these micro- dispersions (PUDs) introduced that could be applied with a spray machine or magnets find each other, with their combined 1970s 2K solventborne (SB) polyurethane brushed and rolled onto the surface. Without forces equating to added physical strength. coatings the high solvent level, the coating would have Hydrogen bonding provides the properties 1970s 2K solvent-free aromatic coatings been too thick to flow and level. of extraordinary hardness and flexibility for 1980s 2K polyaspartic and 1st gen 2K Later in the 1970s, 2K solvent-free aromatic polyurethane-based coating technologies. waterborne polyurethane coatings coatings were formulated. The basic building Another reason polyurethane coatings provide blocks of aromatic coatings, resins and 2000s 2nd gen 2K waterborne polyurethane superior performance is a high crosslink density. hardeners have a low viscosity and do not coatings Crosslinking is entanglement and reaction of necessitate thinning with a lot of solvent to 2000s Waterborne UV-curable coatings polymer chains that increases physical strength make them easy to spread or level. But, they and chemical resistance. The long polymer 2015 Low viscosity polyaspartic technology do still have the issue of color change when chains, with hydrogen bonding, get entangled exposed to light. and linked like a ball of ropes. When one rope and/or tint that provides the performance The first generation of 2K waterborne is pulled, all the ropes follow rather than just characteristics of solvent-based systems with polyurethane coatings, developed in the 1980s, the one. Two-component polyurethane coatings the ease of application associated with water- had adequate but limited physical properties have a higher crosslink density than their based systems. and still contained quite a bit of organic solvent one-component analogs. in addition to the water used to thin the Polyurethane coatings have been around for Crosslinking increases the properties of a formulated coating. decades and have a proven track record. Otto 2K waterborne polyurethane but adds a Bayer first invented polyurethane as a class of Over the past three decades, significant mixing step. 2K polyurethanes are based technology in the late 1930s. The first use of advancements in polyurethane chemistries have on polyurethane dispersions and aliphatic polyurethane as a coating was in the 1940s, as occurred, leading to development of the second hardeners. The PUD component often contains an aromatic hardener-based coating. Aromatic generation of 2K waterborne polyurethanes in multiple other ingredients such as pigments, hardeners posed a challenge in exposed the 2000s. These newer coatings have much additives, and dispersing aids. The other applications because they were susceptible to higher physical properties with ultra-low VOC component is the aliphatic hardener. Like the sunlight and yellowing. For example, when and solvent levels. 1K waterborne PUD, water is added to the the sun hit a blue pigmented, aromatic-based polyurethane dispersion to reach the desired polyurethane coating and the polymer matrix One component polyurethane coatings are ready to use solids content. Solids are what is left after turned yellow over time, this added yellow color right out of the can paint dries and the water or solvents have to the blue hue, eventually giving the coating Chemistry: evaporated. Typically, a 1K or 2K floor coating the appearance of being green. Or, if an 1K aliphatic polyurethane coating based on polyurethane dispersion has a solids content around 50 to 60 percent aromatic hardener-based coating was used as a with the rest being primarily water, solvent, clear coat on top of gray concrete, the concrete Polyurethane Dispersion Air Dry additives, and pigments. The 2K waterborne surface turned beige as the coating yellowed coating cures as it dries and the polyurethane over time. Dries to form dispersion and aliphatic hardener react to form a polyurethane coating. To combat this challenge, scientists developed A Polyurethane Coating aliphatic hardeners for coatings in the 1960s. PERFORMANCE BENEFITS AND DRAWBACKS Due to their molecular structure, aliphatic Crosslinking increases the properties of the 2K waterborne OF 2K WATERBORNE COATINGS hardeners are more color stable, so the polymer polyurethane but adds a mixing step There are many more benefits in 2K than 1K does not break down and yellow over time. Chemistry: 2K aliphatic polyurethane based on polyurethane or polyacrylate waterborne coatings because of the crosslink Waterborne polyurethane dispersions (PUDs) dispersions and aliphatic hardeners density. Properties include excellent durability, were introduced in the 1970s. An aliphatic OCN excellent color, and excellent gloss. A unique Polyurethane Dispersion Aliphatic Hardener NCO polyurethane backbone is made in a reactor and attribute to point out is that by picking out the then dispersed into an aqueous phase using Dry and react to form right PUD resins, a formulator can formulate solvents and water. These early polyurethane a 2K waterborne coating to range from high dispersions, although considered waterborne, A Polyurethane Coating gloss down to matte without requiring matting still had a lot of solvents in them. additives, which compromise physical properties. CONTINUING EDUCATION

The first generation of waterborne coatings had SURFACE PREPARATION AND SAFE USE (1–3 mils) that requires a CSP 1–2 all the way as much as 300 grams per liter of co-solvent, CONSIDERATIONS up to a very thick polymer overlay (125–250 resulting in heavy odor. These coatings would mils) that needs a CSP 4–9. Depending on the Just like any flooring job, concrete surface not fulfill most VOC requirements today. The thickness of the coating, the contractor must preparation is the key to a successful 2nd generation is truly waterborne with less change how rough the surface is to achieve the application. Poor surface preparation is the than 50 grams per liter, and in many cases less correct profile. number one reason jobs fail over time, causing than 10 grams per liter, of solvent, equating over 80 percent of failures. Factors to consider A coating or sealer failure is caused by one of to an ultra-low-VOC coating. These systems are the age and condition of the concrete, three primary reasons: surface preparation, are very low odor and can be used in occupied laitance, porosity, and moisture vapor application issues, and incorrect coating buildings or where there may be sensitivities transmission. application. 80 percent or more of failures are to odor in a commercial environment. This is due to poor surface preparation. Another 15 a truly viable replacement for solventborne When cleaning concrete, solvents should not percent of failures are due to application issues systems, achieving high chemical resistance in be used to remove oil and grease because the including delamination, blistering, or poor a waterborne product without the smell and solvents will draw the oil and grease further mixing that causes physical properties to vary. VOC. In addition, two-component polyurethane down into the concrete rather than picking Only about 5 percent of failures involve the waterborne floor coatings contain no added it up. Instead, detergent or steam cleaning wrong coating being applied to the floor. phthalate, formaldehyde, or heavy metals. should always be used to bring the oil and Because they are aliphatic, they are also light grease out of the concrete. Treat mildew WATERBORNE POLYURETHANE FLOOR and weather stable. with bleach and water. Next grind, polish, or COATINGS ADD BEAUTIFUL DESIGN AND blast the concrete, then vacuum or clean the SUSTAINABILITY AT THE EIC 2K waterborne coatings have a medium to long surface and wait until it is dry. open time (working time) of an hour or two, One of the main goals for revitalizing which is essential with large floors that may not The single most important industry standard the Energy Innovation Center was to use have a seam or joint to work towards. But, they for correct preparation of concrete surfaces energy efficient and environmentally- have a correspondingly long dry time before is the SSPC SP-13 Surface Preparation of responsible construction techniques while they can be put back into service. Be aware Concrete specification. Depending on the finish, still maintaining aesthetic appeal. One that the walk-on time is typically double the there are preferred concrete surface profiles area that attracts particular traffic and dry time, which is tested in a lab. In reality, the (CSP). The CSP rating is the concrete surface attention is the floor. The massive hallways dry times need to double before a 200-pound profile outlined by a set of standards from the in the EIC needed a coating that would person should walk across the floor. Walk-on International Concrete Repair Institute (ICRI). be durable, sustainable, and attractive. time can range from 2 hours to 12 hours The profiles range from a thin sealer or topcoat depending on humidity and temperature. Two-component waterborne polyurethanes have excellent properties as a colorcoat, clearcoat, or low viscosity penetrating sealer for polished concrete and pavers. When used as a sealer the polymer solids level is typically at 25 to 30 percent as opposed to 50 to 60 percent when used as a coating. One coatings manufacturer performed stain testing with a variety of household and industrial chemicals including balsamic vinegar, ketchup, mayonnaise, mustard, transmission fluid, WD 40, power steering fluid, gasoline, motor oil, and ammonia. Even at 30 percent solids, the 2K system was able to resist staining or degradation. At slightly higher solids, it can even be used as a coating in airplane hangars because it is resistant to Skydrol, an aggressive chemical that can leak out of airplanes and will damage conventional coatings. The drawbacks of 2K waterborne polyurethane coatings are very similar to other waterborne coatings in that cold weather and high humidity lengthen the cure time. In addition, the After 80 years of heavy use, the EIC’s 20,000 square feet of concrete floors were severely cracked and spalled, and significant concrete repair contractor needs to be familiar with mixing a work was needed to create an acceptable surface to coat. A polyurethane-based coating was specified for its low volatile organic compound two-component system. content, which is critical to the EIC’s LEED platinum certification. CONTINUING EDUCATION

After 80 years of heavy use, the EIC’s 20,000 square feet of concrete floors were severely cracked and spalled, and significant concrete repair work was needed to create an acceptable surface to coat. A polyurethane-based coating was specified for its low volatile organic compound content, which is critical to the EIC’s LEED platinum certification. UV-stability, durability, longevity, and excellent chemical and abrasion resistance were also desired characteristics inherent to the product. Once major flaws were addressed with mortars and sealants, a cementitious overlay was applied to the entire floor, which was used to level the floor and prepare it to accept a high-performance coating system. The overlay was applied at a thickness of ¼" to 3/8", with some badly damaged areas receiving up to 2" of overlay. The material was spread with gauge rakes to even it out and was allowed to cure a minimum of two days before being lightly sanded. Next, a 100% solids epoxy basecoat was applied at 20 mils to even out the color A 2K waterborne polyurethane clear coat was also used to coat an original 5/4" maple wood floor that was installed in what used to be a and promote long-term adhesion, and a machine shop training room. two-component waterborne polyurethane was actually desirable and added character topcoat was selected by the EIC design team versus a very light maple, which would have to protect and seal the surface. 2K waterborne emerged upon sanding. Coatings will not stick polyurethane coatings offer high durability, to oily surfaces, so the owner’s first attempt ultra-low VOC and low odor, with excellent at using a standard floor coating only lasted a gloss and workability. Two coats of waterborne month. A coatings manufacturer came in and polyurethane floor coating were applied as the did extensive testing in oily areas with various clear protective topcoat to the floor surface high-performance waterborne polyurethane with a dip and roll technique using a 3/8" coatings. The final coating has similar chemistry nap roller and a wet film thickness of 6–7 to that installed on the concrete floor, but the mils. The waterborne floor coating technology manufacturer specifically formulated it for was available in a satin finish, which was a wood floors. The owner chose a lower satin desired design attribute of the owners since sheen because the room is on an upper level they wanted to retain the neo-industrial look with many windows and they did not want it to throughout the building. The Connelley School machine shop in 1954. This shop was designed be too glossy, bright, and reflective. to resemble a modern factory, where students were destined after The results? Durable, long-lasting flooring that 18 graduation. The maple floors are now a highlight of the is both beautiful and in line with the goals of 2,1500 square foot BrightSpace, an event the Energy Innovation Center. Because the application has been in use for five years and space and conference room with a 725 square floor coating was also ultra-low VOC, it helped demonstrates the long-term performance of the foot adjoining classroom, both overlooking the support Pittsburgh Gateway’s desire to achieve polyurethane based coating system. Allegheny river. LEED Platinum certification. A fully restored, WOOD FLOORS IN BRIGHTSPACE ROOM continuous walkway throughout the building 2K WATERBORNE POLYURETHANE DRY COATED WITH A SIMILAR TECHNOLOGY blends into the updated neo-industrial décor ERASE COATING HAS A CLEAR ADVANTAGE19 that the owner envisioned. The floor finish A 2K waterborne polyurethane clear coat was A ground-breaking coating technology with imparts a homogenous look to a very large also used to coat an original 5/4" maple wood origins in the anti-graffiti market makes space, and the lower satin sheen eliminates floor that was installed in what used to be a heavy, clunky physical whiteboards a thing glare and reflections from the many overhead machine shop training room. The floor had of the past. Dry erase clear gloss coating is a skylights. Because the area was constructed machine oil stains and a lot of damage, but the two-component, water-based polyurethane with very few day joints, saw cuts, or other owner wanted to salvage this beautiful floor for for use over prepared interior surfaces where breaks in the surface, having a coating system aesthetic and sustainability reasons. Where oil a writeable, erasable surface is needed. The with a long working time was crucial. This floor had soaked in it had a darkening effect, which CONTINUING EDUCATION

coating has less than 100 g/L VOC, and excellent and new construction. With the ability to sketch Two rooms in the Energy Innovation Center durability so it will not crack, peel, fade, or lose a vision right on the wall, they are perfect for received a ‘dry erase paint’ coating based on its finish over time. The durable finish easily conference rooms to get creative brainstorming 2K waterborne polyurethane technology. The wipes clean with a dry erase eraser or soft cloth going and encourage group participation. In coating allows the room occupants to write with no ghosting or shadowing left behind. schools, a dry erase coating provides easy clean anywhere on one of the walls in the room in up compared to traditional chalkboards and lieu of a dry erase board. This surface replaces Unlike traditional white dry erase coatings, this whiteboards, with the writing space limited only standalone or wall-mounted whiteboards so crystal clear transparent coating is applied over by the size of the wall. They can even be used that users aren’t confined to a smaller board a desired background color, providing maximum at home to replace traditional bulletin boards or and are free to brainstorm. Before application, versatility and functionality that works with the in playrooms where creativity can run wild. the manufacturer tested for ghosting and established aesthetics of the room. The clear shadowing, as well as high sheen maintenance gloss finish allows you to turn most walls into The two-component system is designed for to ensure the dry erase continues to work a dry erase board without sacrificing the wall’s professional application only, applying with properly. They wanted to make sure that the original color. Once professionally applied, the brush or roller and cleaning up easily with marker ink does not bead up on the coating. coating dries to a smooth, clear gloss surface water. The coating dries to the touch in 4 to 6 The room was painted, and then a clear, that is non-yellowing and ideal for use in any hours and cures in just seven days for use with dry-erase coating was applied. It has been in commercial, educational, or residential space. any standard dry erase marker. If dry erase is place for three years with no signs of yellowing, no longer desired the coating is simple to paint Dry erase clear gloss coatings are often used in ghosting, or shadowing. ◾ over—lightly sand the wall, apply a quality schools, offices, homes, commercial buildings, primer, and apply a new topcoat to the surface.

REFERENCES 1 https://www.spraypolyurethane.org 11 https://www.dlaplus.com/pages/energy-innovation-center 2 https://www.polyiso.org 12 https://www.covestro.co.th/en/industries/construction 3 http://www.eicpittsburgh.org/about/history/ 13 http://www.eicpittsburgh.org/about/building/ 4 http://www.eicpittsburgh.org/wp-content/uploads/2015/08/eic-brochure_hist.pdf 14 Energy Innovation Center – Pittsburgh Spray Polyurethane Foam for 5 http://www.eicpittsburgh.org/wp-content/uploads/2015/08/eic-brochure_hist.pdf Commercial Applications 15 6 Covestro EIC Case Study, Cost-effective Roofing Innovation - Polyiso Board Covestro EIC Case Study, Cost-effective Roofing Innovation - Polyiso Board Insulation Insulation 16 7 Covestro EIC Case Study, Covestro Waterborne Polyurethane Floor Coatings Aid http://sprayfoammagazine.com/ in Beautiful Design and Sustainable Future at the Energy Innovation Center spray-foam-insulation-helps-depression-era-building-go-platinum/ 17 8 http://www.eicpittsburgh.org/about/building/ Covestro EIC Case Study, Cost-effective Roofing Innovation - Polyiso Board Insulation 9 http://www.eicpittsburgh.org/about/building/ 18 http://www.eicpittsburgh.org/about/history/#!mg_ld=2044 10 https://www.nps.gov/tps/standards/applying-rehabilitation/successful-rehab/ 19 energy-efficiency.htm https://images.sherwin-williams.com/content_images/SW-PDF-DRYERASE.pdf