Industrial Wall Restoration for INNIO Manufacturing Facility

in Waukesha, WI

Location

Waukesha, WI

Client and Facility Overview

INNIO, a global leader in energy solutions, operates a manufacturing facility in Waukesha, Wisconsin. The facility is integral to their Waukesha product line, which provides power generation solutions for both traditional and green energy applications. As part of their extensive manufacturing operations, the facility maintains strict quality standards to support their 50-year legacy of delivering reliable energy solutions. The north wall of their manufacturing area serves as a critical production zone requiring regular maintenance to maintain operational standards.

Requested Maintenance

The client requested a comprehensive color scheme update for the manufacturing area's north wall, transitioning to orange and gray colors to align with corporate standards. The scope included addressing several surface challenges:

Surface Deterioration: Areas showing water damage and paint failure required remediation
Contamination Removal: Existing grease and efflorescence needed thorough cleaning
Wall Restoration: Areas behind removed shelving revealed additional surface deterioration requiring attention
Safety Markings: Integration of four fire extinguisher wall markings within the new color scheme

The project demanded a methodical approach to surface preparation and coating application, with particular attention to maintaining operational cleanliness and safety standards throughout the process.

Decision Driver and Timing

The project was driven by multiple factors affecting the facility's operational standards:
Surface Degradation: Discovery of extensive paint failure and water damage behind removed shelving units necessitated immediate intervention
Facility Standards: Need to maintain consistent corporate aesthetic with specified orange and gray color scheme
Safety Compliance: Requirement to properly mark and maintain fire safety equipment locations
Operational Impact: Timing coordinated during weekday first shift to align with facility operations while ensuring proper access for thorough remediation

Scope of Work

Surface Preparation:

Implementation of dry-ice blasting technology for effective removal of efflorescence, failing paint, and grease
Additional surface preparation including cleaning and necessary wall repairs
Spackling and patching of damaged areas to ensure uniform surface quality

Coating Application:

Upper Wall Areas: Application of two coats of acrylic Multi-Surface Industrial Enamel
Lower Wall Areas: Enhanced protection with three coats of acrylic Multi-Surface Industrial Enamel
Integration of four fire extinguisher wall markings within the new color scheme

Project Management:

Establishment of Controlled Access Zone (CAZ) with clear boundary marking
Coordination of additional resources when expanded scope was discovered
Management of supplemental work order for two totes of dry ice and 20 additional man hours

Safety Protocol:

Implementation of comprehensive OSHA-compliant safety measures
Utilization of proper PPE including spray suits, respirators, and safety equipment
Installation of safety cones and caution tape to define work areas
Strict adherence to aerial lift safety requirements including certification verification

Notable Details

When shelving removal revealed additional surface deterioration, the team quickly assessed the situation and secured appropriate work order adjustments to maintain quality standards

Successfully incorporated additional resources, including two totes of dry ice and 20 extra man hours, while maintaining project efficiency

Established comprehensive Controlled Access Zone (CAZ) with red boundary tape, ensuring clear communication of restricted areas to facility personnel

Differentiated coating applications between upper and lower wall sections to provide optimal protection and appearance based on area exposure and wear patterns

Executed work during first shift operations, demonstrating ability to maintain productivity while accommodating facility's ongoing operations

Client Satisfaction

The project concluded with high client satisfaction, meeting both timeline and quality expectations despite the discovered additional scope requirements. The successful execution of this project has led to strengthened client relations, with INNIO confirming future project opportunities at their facility. The team's professional handling of the expanded scope, coupled with effective communication regarding the additional requirements, demonstrated Painters USA's commitment to quality and client service. The restored north wall now properly reflects INNIO's corporate standards while providing improved protection against industrial wear and environmental factors.