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Author
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Topic: Potholes in my floor!
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Aaron Sisemore
Flaming Ribs beat Reeses Peanut Butter Cups any day!
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Posts: 3061
From: Rockwall TX USA
Registered: Sep 1999
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posted 06-12-2005 01:20 AM
That floor is unfortunately not concrete, but a 3-inch thick layer of 'Gypcrete' which has awesome sound-deadening properties, but for all intents and purposes is about a point or two tougher than plaster-of-Paris. To seal the Gypcrete and make it basically indestructable, it was to have several heavy coats of epoxy paint coated on it.
Well... (the story that I have received on this situation)
Apparently some painting contractor that didn't know better decided that the epoxy paint generated too many noxious fumes.
So this Einstein goes ahead and coats the floor... with two or three coats of LATEX paint... Voila! No noxious fumes!
By the time that word of the error got to the developer and Cinema West management, it was too late, as many pieces of [very heavy projection and sound] equipment had already been hauled up to the booth and set in place (I was on vacation during this portion of the install, so I had little say in what went up there and when- also it was assumed that the contractor had done the floor properly.) Of course, moving the projector bases and platters around when they brought it all up there gouged the hell out of the floor, leaving some of the 'potholes' that Dom is describing, and in other places, the latex paint began to simply bubble and peel off the floor.
About six months later they tried to do something as a stopgap fix, but it was only a single layer of eopxy paint, no equipment was moved to lay it down, and we couldn't close the theatre down long enough (at least 1-2 days) to allow both the painters to actually lay down several coats of the paint, and allow the fumes to subside so that we weren't making the entire place ill from the fumes, and to allow multiple coats to properly cure.
Apparently this same genius painter decided that the latex paint was fine for the concrete floors in the auditoria as well, as they are also a mess of peeled, spotted and repainted concrete.
I don't know if the painter that caused all this trouble ever lost his job or not.
-Aaron
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William Hooper
Phenomenal Film Handler
Posts: 1879
From: Mobile, AL USA
Registered: Jun 99
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posted 06-13-2005 01:08 AM
Tracy's got the right answer for prepping the hole for the patch, but the surrounding area & the rest of the floor, to get the finish neccessary as Aaron mentions by applying 2-part epoxy paint, will have to be prepped with muriatic acid.
This is probably what the painter fled from. Prepping with muriatic acid can put little holes & acid burns in your skin (including face) without covering up. Also, if the room is not completely stripped & you're doing the whole room, it will get at the paint on seat standards, start eating away at exposed conduit & other metal, etc.
It looks like one of those 'if it's not done right the first time you'll be battling it forever' problems. You could pull all the seats out, strip the old paint, fill the holes, prep with muriatic acid, & put on a couple of coats of 2-part epoxy paint as was originally spec'd, or come up with some method of dealing with the deterioration as it occurs (patching the hole, painting, & being aware that it will have to be done again sooner or later).
If the holes are localized, & recurring in the same spots (like between a couple of rows or down front), it might be worth it to re-do that area only (the row, entire area in front of the screen, whatever), by stripping, filling, prepping & painting with 2-part epoxy. If it's coming up everywhere - under seats, new places everywhere - fixes short of pulling it all out & doing it right are just going to be like bailing water in a hurricane.
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