Solution:
The A&I Endurafast system was selected — a rapid-cure, hard-wearing coating based on specialised acrylic resins. Its radical polymerisation cure process ensures performance even in cold conditions, making it ideal for urgent applications where traditional coatings fail.
Located in the historic city of Ballarat, Victoria, St Patrick’s College, Newington required an urgent upgrade to a vehicle-access ramp leading to a service building. The ramp, acting as a delivery driveway, had a gentle to moderate incline and was previously coated with a thin-set epoxy with grit to provide traction. However, the slope and aggregate size meant the surface did not provide adequate slip resistance, creating a safety hazard.
The challenge was compounded by cold winter temperatures (0–6°C) and a limited 10-hour daily window free from dew condensation, which required a solution that could cure rapidly and perform immediately. Traditional epoxy and polyurethane coatings were not suitable under these conditions.
1. Surface Preparation: Full diamond grinding performed the day before installation.
2. Drying: Substrate dried using gas-operated heaters to remove moisture.
3. Coating Application: Four layers of Endurafast applied over 6 hours, with 40-minute cure times between coats.
4. Slip Resistance: Large, kiln-dried quartz aggregate (>1mm) cast to refusal within the coating to deliver a coarse, high-traction finish.
Endurafast proved to be the ideal solution for St Patrick’s College, providing a safe, durable, and rapid-cure finish where traditional coating systems would have failed. This project highlights the importance of selecting the right coating system for challenging environments and tight schedules.
The Pakenham Station redevelopment exemplifies the successful integration of advanced digital fabrication techniques in public infrastructure projects. A&I
Coatings, working alongside ShapeShift, delivered an ultra-high-performance coating for the ShapeShell™ RT panels, contributing to a sustainable,
efficient, and architecturally distinctive station that serves as a model for future infrastructure projects.
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