Sep 15

Clean Room Case Study Using Kemlite FRP

Construct a certified clean-room retrofit for medical product manufacturing with the following features:

  • Custom 14’ ceiling heights without horizontal seams
  • Highly reflective and cleanable seamless surfaces
  • Durable surfaces that resist damage from moisture, chemicals or cleaning agents
  • Cost effective long-term performance and no maintenance

The 23,000 sq. ft. space featured 14’ ceilings and wall substrates including plywood and drywall. The project plan called for FRP panels that would extend to the ceiling without horizontal seams. In addition to meeting clean-room certification, the client wanted seamless wall and ceiling surfaces for minimal maintenance, long-term performance, and ease in cleaning. 

FRP panels were the top consideration for construction, based on known performance characteristics, installation ease and long-term cost-effectiveness. Other potential options considered, but rejected included: lower-cost epoxy paint and/or silicone sealants, which would require ongoing maintenance and installation complexity.

SOLUTION

Crane Composites was selected based on three key factors:

  • Proven product quality, performance and installation ease
  • High levels of personalized service and hands-on product support
  • Ability for panel customization 

OUTSTANDING PRODUCT PERFORMANCE

The solution for this clean-room was Glasbord panel, combined with Crane Fast Grab adhesive and Crane Polyurethane Seam Sealant, all independently tested and certified for cleanroom applications.

Glasbord with Surfaseal anti-microbial finish ensures that the surface will not trap soil or bacteria. Glasbord panels meet USDA/FSIS requirements. The Fast Grab solvent-free adhesive is formulated for superior panel adherence on plywood and drywall substrates.

Crane Seam Sealant is a fast-curing extremely low VOC urethane sealant specifically designed for seamless performance in clean-room applications. The two-part Seam Sealant bonds with Glasbord to create a monolithic surface for trim-free superior cleanability, low particle emission, biological and chemical resistance. The surface does not require maintenance and is particularly durable and resistant.

SERVICE AND SUPPORT 

The client will realize long-term returns on its investment. The clean-room is built for durability, ease in cleaning and will remain virtually maintenance free for years to come. Additionally, the high surface reflectivity will help lower lighting costs over time.

CUSTOMIZATION

For this project, the Crane Composites team was able to address the 14’ ceiling height and request for no horizontal seams by quickly supplying custom sized FRP panels. Glasbord FRP panels and all Crane Composites products, are produced at manufacturing facilities locally in the USA, so custom panels can be delivered on short-notice and cost-effectively.

BENEFITS

  • Ease of FRP installation for labor cost savings
  • Glasbord meet USDA/FSIS requirements
  • Proven material properties and sealant that ensures virtually no maintenance
  • Seamless, monolithic wall panels do not produce or trap airborne particles
  • Superior chemical and biological resistance validated by independent lab tests
  • Smooth surface prevents buildup with superior cleanability
  • Documented extremely low VOC components
  • Significant cost savings in total installed cost versus alternative wall systems
  • Reduced installation complexity versus PVC and epoxy systems

 

Sep 01

Washroom Stalls – Truly Sustainable Designs

In essence of the Greenbuild International Expo this week in New Orleans we feel that discussing sustainable material options for your restroom and locker room products are very important.

When you choose Scranton Products Hiny Hider Partitions, Resistall Partitions, Tufftec Lockers or Duralife Lockers you are supporting a healthier environment. Our products reduce industrial waste by using a blend of virgin and pre-consumer recycled content to produce a high quality product that is 100% recyclable.

sustainable_designGREENGUARD Gold Certified our products meet strict criteria intended for use in environments where children and adults spend significant periods of time. Because our products never need painting, they do not contribute to VOC emissions, which improves both indoor and outdoor air quality. In addition, they can be power-washed or steam cleaned, eliminating the need for harmful chemical cleaners. Incorporating our products can contribute points toward LEED certification as well. To learn more about Greenguard Certifications you can follow this link. Greenguard Certification

Scranton Products incorporates 25-100% pre-consumer content in all of our products allowing us to help achieve our goal of being a zero landfill facility and providing our customers with a greener solution to our materials. For those customers looking for a little bit more of a sustainable product we offer our Hiny Hider HDPE (high density polyethylene) partitions in 100% post consumer content. Our HDPE materials do not contain any added Urea-Formaldehyde resins and have an downstream process for recycling.

Sep 01

Dasher Boards Re-Built with Puck Board and to Reuse Tempered Glass

Retrofi Dasher Boards at the Badeque ArenaA former settlement for a large number of United Empire Loyalists who landed following the American Revolution, Bedeque was deemed “the place that lies on the backward turn” by Native settlers.

One of the Island’s most heavily farmed regions, the community is situated amongst endless potato fields, calling to mind the vital role agriculture plays in the well-being of so many Islanders. The Bedeque Bay, into which the Dunk River empties, teems with a variety of wildlife and is a popular destination for many anglers.

In this small community, the recreation centre is the hub in which a great meny of this towns activities revolves around.

In June 2015 Sound Barriers completed a re-build of the Badeque & Area Recreation Centre arena.

The rebuild consisted of manufacturing new steel frames on site to accommodate the existing arena footprint. HDPE white puckboard was then attached using countersunk colour matched screws. Yellow puckboard kick strip and red puckboard top sill were then installed again using countersunk colour matched screws.

Puckboard, is a versatile, adaptive plastic material. Made of robust HDPE (High Density PolyEthylene). Puckboard is durable resilient, and can take high impacts without cracking or breaking even in cold temperatures. Puck board is the idea product for arena dasher boards. Puckboard is available in a wide range of colours and thicknesses.

In the design and manufacturing of the dasher board steel frame, Sound Barriers was able to place the aluminium stanchions in such as manner as to reuse the tempered glass barriers in the system, reducing the overall cost rebuild to the arena.

Aug 01

What's the CORE Problem in Restroom Stalls?

core_problem

There are many choices when choosing a material for your bathroom partitions. Before making a decision take a closer look at whats inside!

Material Options

The five main material options when choosing a bathroom partition are; Plastic laminate, Phenolic (black core), Stainless Steel, Baked Enamel, and Solid Plastic. All of these material choices vary in cost and have different cost of ownership models.

My Core is What?

Plastic laminate partitions are made from particle board and finished in a plastic laminate surface.

Phenolic (black core) partitions are compression molded; made from many layers of decorate papers which are saturated with phenolic resin. This forms the base which is then laminated with heat.

Stainless Steel partitions are generally manufacturered with a honey comb or wood core glued under pressure to #304 stainless steel sheets and assembled with roll formed molding.

Powder coated steel or baked enamel is a hybrid epoxy / polyester powder coated finished over galvanized steel is fabricated with roll formed molding and a honeycomb or woodcore.

Solid plastic is made from a polymer composed from extruded resin and is solid throughout.

How Cores Affect You

A source of potentially harmful air quality issues occur with exposure to mold, mildew and fungus.

Veneer exterior, particle board and honeycomb cardboard cores are at high risk for moisture penetration. This risk increases dramatically when these materials are placed in damp and wet environments such as shower rooms and restrooms.

Laminated or hollow core materials cannot be installed without penetrating the veneer exterior, exposing the interior to moisture and potentially water. This can create a harmful condition whereby the core of the partition becomes exposed to moisture while the thin veneer remains seemingly intact. As the core begins to mold and deteriorate, the integrity of both the air quality and partition structure are compromised.

This could result in an unforeseen hazardous and costly mold problem. This is particularly true in rooms with increased humidity such as showers, restrooms and locker rooms

Utilizing solid surfacing materials such as HDPE contributes to better indoor air quality as the solid, non-porous property of these materials resist the growth of mold and mildew.

Aug 01

Barrie Allandale Arena Selects ProXL Resilient Rubber Flooring

Allendale Arena - Barrie OntarioThe Allandale Recreation Centre (ARC) is located at 190 Bayview Drive in Barrie Ontario. This facility features two arenas (100’ x 200’ International and 85’ x 190’ North American), a 25 meter pool and toddler pool, a banquet/meeting hall with full kitchen, fitness centre and food concession area.

Sound Barriers supplied and installed 6000 sqft of ProXL resilient rubber flooring to service the arena dressing rooms and common areas. This project was completed in May 2015.

One of the challenges of the installation was to fully remove the worn existing flooring. After removing the existing flooring, Sound Barriers fully cleaned the substrate, removing any contaminates and residual adhesive, for a clean and reliable fitting of the resilient rubber tiles.

Allendale Arena opted for ProXL 512 grey/black tiles, a solid colored, dual layer, marble accent rubber flooring tile. ProXL’s slip-resistant, textured top wear layer provides a non-porous, safe and resilient floor finish.

ProXL is a dual-layer, vulcanized rubber designed for durability. Its’ slip resistant surface is ideal for arenas and recreational facilities.

Aug 01

SCRANTON PRODUCTS REVOLUTIONIZES SCHOOL STORAGE WITH NEW DURALIFE® HDPE, FIRE-RATED LOCKERS

Scranton, PA – It can seem like a jungle in school hallways, with kids slamming, swinging and sounding like a herd of elephants- releasing all that pent up energy on their poor lockers! Welcome to the jungle says Scranton Products, as they introduce Duralife® Lockers, the only line of solid HDPE school lockers that are fully fire-rated (compliant with NFPA 286) as well as being GREENGUARD Children & Schools CertifiedSM for improved indoor air quality. With extensive advantages over metal lockers, Duralife features the strength and durability to stand up to the bombardment of everyday school use with low maintenance at a comparable cost. Duralife Locker doors also feature a quieter close, reducing noise levels by three times that of metal lockers. A new Duralife video detailing the advantages is available at https://vimeo.com/48979521.

Duralife Lockers from Scranton Products on Vimeo.

“Duralife Lockers, made with HDPE, are a stylish, economical alternative to metal,” said Don Wharton, President of Scranton Products. “With the multitude of durable, easy care features, the payback is realized in just a few short years.”
American-made Duralife Lockers are available in several design options and15 beautiful colors, with a color-throughout formula that resists scratching. Custom color options are also available. With a 6-point latch mechanism and full length anodized steel hinges for exceptional strength, Duralife Lockers are impact and dent resistant. In fact, in ASTM impact testing, they were shown to have 59 times the impact resistance of metal. They will not rust, corrode or delaminate and are covered by a full 15-year warranty.
HDPE is naturally resistant to bacteria, odors, mold and mildew and the non-porous surface is very easy to clean. Graffiti wipes off easily with most non-abrasive cleaners and stickers and contact paper are easily removed. The lockers can also be power washed and steam cleaned without the worry of rust.
In addition to meeting GREENGUARD Children & Schools air quality standards, Duralife Lockers also contribute to a project’s LEED certification. They are made with recycled materials and are 100% recyclable. And, since they do not require painting, there are no VOCs.
Duralife Lockers perform far beyond metal and will stand up to the stampede!

Jul 20

Sound Barriers Uses Kingspan Insulated Panels For 2015 Toronto Pan Am Games Athletes Village Cafeteria

Pan Am Kingspan BuildThe Pan Am Games Athletes Village, located near Front St. and Cherry St., is ready to host around 7,100 athletes, coaches, and trainers from countries across the North America, South America, Central America and the Caribbean when the games kick off in mid-July. Everything the competitors could need is within walking distance, from accommodations to laundry services to a gym, and dining hall.

Working with Roberts On Site (http://www.robertsonsite.ca/), Sound Barriers completed the cafeteria and refreshment areas of this project in April 2015.

This temporary facility provides the cafeteria, kitchens, coolers, production areas, serving areas and refreshment areas for the Pan Am athletes.

Sound Barriers used Kingspan (http://www.kingspan.com/) 70mm insulated panels to construct the main structure within the larger tented area. This installation also included Superseal traffic doors and cooler/freezer doors.

Kingspan offers the best lineup of high performance, cost and energy efficient insulated metal wall panels and roof systems in the industry. It starts at the factory, where the single component systems are built. This eliminates the need for multiple trades, which increases build time and diminishes delays. The single component insulated metal wall and roof systems built by Kingspan can reduce on-site installation time by up to 50% compared to traditional multi part site assembled built-up systems.

Kingspan Ceiling InstallationHigh performance and efficiency start in the factory and continue throughout the lifetime of the panel. This is possible because Kingspan insulated wall systems offer superior R-values (7.5 per inch) with unparalleled thermal performance during service life. One key factor to the panels’ efficiency is the fact that the insulation is on the exterior of the building structure to provide the best possible thermal envelope by reducing thermal bridging typical of cavity wall systems. And to complete it all, the moisture resistant panels feature excellent foam-to-foam contact, which provides an unbroken thermal shield against heat transfer.

As an added benefit, testing and field results show that insulated metal panels (IMPs) contribute to ROI and energy efficiency. Which means adding Kingspan’s metal roof and wall system optimizes a building’s performance and it becomes the first step towards NetZero energy. This is know as the EnvelopeFirst™ approach to design, a focus on enclosure performance including durability, airtightness, and better moisture and thermal control.

Superseal Series 2000 flexible vinyl impact traffic door were used to provide quick ingress and egress for product suppliers. Designed for door openings up to 10′ W X10′ H, The Series 2000 Vinyl impact door is the most economical solution for applications where wide loads are forced to pass through narrow restricted openings. The tough, durable door panels are suspended from gravity hinges at the top only, providing unobstructed passage. No lower hinge hardware to be damaged or width reducing jamb guards. The hinge hardware allows the door to open with impact and return gently to a closed position. Available in several colours the tough reinforced vinyl fabric and standard impact plate(s) make this door ideal for pedestrian, push cart, light motorized and forklift traffic. Thermal models are available where temperature control is necessary. A wide selection of window options permits safe, speedy traffic flow while conserving energy.

Reduce, Reuse, Recycle

Since this is a temporary structure for Pan Am Games use, Sound Barriers will be de-installing the building materials used, and repurpose them for other industrial/commercial applications. Thereby reducing waste entering our landfill and making this a “Green” rated structure.

Apr 01

FRP Panels are Acceptable for Use in ISO Classes 5-8 Cleanroom Applications

Cleanroom ProductThanks to the exclusive Surfaseal finish, Glasbord is the perfect solution for applications requiring cleanability, low particle emission, biological resistance and chemical resistance.

Glasbord is the industry leading fiberglass reinforced plastic (FRP) panel. The homogeneously applied Surfaseal finish means that the surface is sealed and will not trap soil or bacteria.

The system features Crane Composites’ Glasbord panel. The Glasbord panels are available with a Class A or Class C fire rating per ASTM E-84 with a smooth or embossed finish. The Glasbord FSFM panel has been tested and certified by independent third parties. The cleanroom certified FRP wall panels are completed with the use of biological and chemically tested adhesive and seam sealant for wall panel applications and trim-free seams.

Applications

Biotechnology | Pharmacy | Medical Devices | Hospitals | Pharmaceuticals

Mar 19

Gardner Impact Test

Falling dart impact, also known as Gardner impact, is a traditional method for evaluating the impact strength or
toughness of a plastic material. The test is often used to specify appropriate materials for applications involving impact or to evaluate the effect of secondary finishing operations or other environmental factors on plastic impact properties.

The test sample rests on a base plate over an opening of specified diameter. An “impactor” sits on top of the test
sample with a nose of specified radius in contact with the center of the test sample. A weight is raised inside a guide tube to a predetermined height, then released to drop onto the top of the impactor, forcing the nose through the test sample. The drop height, drop weight, and the test result (pass / fail) are recorded.

The most common method to analyze this data is called the “Bruceton Staircase” method. A number of samples are
used to bracket the pass/fail energy level. Then a series of 20 impacts are conducted. If a test sample passes, the
drop height is increased by one unit. If a test sample fails, the drop height is decreased by one unit. The results from the 20 impacts are used to calculate the Mean Failure Height the point at which 50% of the test samples will fail under the impact.

Mar 19

What is FRP?

FRP, fiberglass reinforced plastic, is a composite made from fiberglass reinforcement in a plastic (polymer) matrix. A construction analogy would be the steel reinforcing bars in a concrete matrix for highways.

By reinforcing the plastic matrix, a wide variety of physical strengths and properties can be designed into the FRP
composite. Additionally, the type and configuration of the reinforcement can be selected, along with the type of plastic and additives within the matrix. These variations allow an incredible range of strength and physical properties to be obtained. FRP composites can be developed specifically for the performance required versus traditional materials: wood, metal, ceramics, etc.

Engineers can design the FRP composite to provide the needed characteristics, and avoid cost penalties of an
over-engineered product.

What is Fiberglass?

Fiberglass fibers are made from molten glass extruded at a specified diameter. The fibers are gathered into bundles
and the bundles combined create a roving. Rovings are a continuous rope, similar to twine, and are wound on a
mandrel to form a ball called a doff. Reinforcements for FRP are made from rovings that are chopped into short
strands, woven into a cloth or used as continuous roving.

There are many factors that affect the reinforcement characteristics of fiberglass:

  1. Fiber and bundle diameter and type of glass
  2. Direction of the fiberglass reinforcement
  3. The amount of fiberglass reinforcement
  4. The physical contact (wetout) of the fiber with the polymer

All of these factors must be taken into account when designing an FRP composite so that the required physical
property strengths are met.

What are Plastic/Polymers?

There are two basic types of plastics/polymers: thermoplastic and thermoset.
In general, FRP composites utilize a thermoset plastic.

A plastic in which the polymer molecules are not crosslinked (not chemically bonded to other polymer molecules) is a thermoplastic. Since the molecules are not connected by crosslinks, it allows the molecules to spread farther apart
when the plastic is heated. This is the basic characteristic of a thermoplastic; the plastic will soften, melt, or flow when heat is applied. Melting the plastic and allowing it to cool within a mold will form the finished product.

Typical thermoplastics are: polyethylene (PE)– used in making garbage bags; polyvinyl chloride (PVC)– used for house siding; and polypropylene (PP)– used as carpet fibers, packaging, and diapers.

A plastic in which the polymer molecules are crosslinked (chemically bonded) with another set of molecules to form a “net like” or “ladder-like” structure is a thermoset. Once crosslinking has occurred, a thermoset plastic does not soften, melt, or flow when heated. However, if the crosslinking occurs within a mold, the shape of the mold will be formed. Typical thermoset plastics are: unsaturated polyester (UP)– used for bowling balls and boats; epoxy– used for adhesives and coatings; and polyurethanes (PURs)– used in foams and coatings.

In addition to these basic characteristics, polymers provide the FRP composite designer with a myriad of
characteristics that can be selected, depending on the application. Combined with reinforcement of the polymer matrix, a vast range of characteristics are available for FRP composites.