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Epoxy Surface Plate
   " When Accuracy Matters "

 


Target Chip Ganassi Racing Project

Electronic Scales Installed Flush in Plate

 

 

Precision Epoxy Products
a division of : Rock Art, Ltd.
4279 Midway Drive
Douglasville, Georgia 30134

Phone : (770) 489-0340

 

 


 

    In June of 2004 we were contacted by Ben Bowlby, Designer, Chief Technology Officer and Head Engineer at Target Chip Ganassi Racing with Felix Sabates in Indianapolis, Indiana. We discussed the possibility for Precision Epoxy to install an Epoxy Surface plate at the Ganassi Research and Development Facility that would accommodate the placement of a set of electronic scales flush within the epoxy surface plate and have the connecting wires routed under the plate and within the concrete substrate to connect with the scales’ read-out display positioned on an adjoining computer work bench located beside the plate. After several discussions regarding this project we were told that if this installation meet with their expectations, that they would be interested in the same type Epoxy Plate installation at their Indy Car / Daytona Prototype Car facility in Indianapolis as well as their new NASCAR facility in Concord, North Carolina. In addition, the Epoxy Plate was being considered for the remodeling project at the recently vacated Team SABCO Racing facility to be occupied by FitzBradshaw Racing. Precision Epoxy worked out the design requirements and application techniques for the initial project and was ready to proceed.

 

    On July 18, 2004 we completed the Epoxy Surface Plate installation at the Team Ganassi R & D facility under a mutually agreed upon Confidentiality Agreement to protect both our proprietary interest. This experimental Epoxy Plate installation not only had the scales flush in the plate, the plate was installed flush in the floor. I am not at liberty to comment on the Team Ganassi R & D Project any further; however, on August 25, 2004 we completed installation of 2 each 12’ x 20’ On-Floor standard type Pro Epoxy Surface Plates at the FitzBradshaw Racing NASCAR facility in Mooresville, North Carolina. On October 12, 2004 we completed installation of 1 each 12’ x 20’ Pro Epoxy Surface Plate with Scales Flush in Plate at the Chip Ganassi Racing Teams NASCAR facility in Concord, North Carolina. On November 23, 2004 we completed installation of 2 each 12’ x 20’ Pro Epoxy Surface Plates with Scales Flush in Plate at the Chip Ganassi Racing Teams facility in Concord, North Carolina. On September 26, 2005 we completed installation of 1 each 10’ x 20’ Pro Epoxy Surface Plate with Scales Flush in Plate and Plate Flush in Floor at the Chip Ganassi Racing Teams Indy Car facility in Indianapolis, Indiana. On October 24, 2005 we completed installation of 2 each 12’ x 20’ Pro Epoxy Surface Plates with Scales Flush in Plate at the Chip Ganassi Racing Teams facility in Concord, North Carolina. That totals 9 Pro Epoxy Surface Plates altogether.

 

 

 

   

 


 

    The Installation of a Pro Epoxy Surface Plate with Scales Flush in Plate will need recessed areas in the concrete substrate at desired locations to accommodate the wheel base of the vehicle or vehicles you will be scaling. The recess areas can be made a part of a new floor design and installed when the new concrete is poured or for existing concrete floors, will need to be saw cut and chiseled out. The following is a design drawing to give an idea for a possible layout. Your needs may vary to suit your particular project or vehicle and we can accommodate any configuration you desire.

 

All measurements above are shown in inches.

 

    The drawing above is for a set-up plate that has the front scale pads in a fixed position. The rear set of scale recess areas are rectangular to allow for the scale pads to be moved forward or backward within the recess area in order to accommodate vehicles with different length wheel bases. This plate can be used for a NASCAR Truck, Busch or Cup car.

 

 

    We found that the above lay-out has the car centered on the Epoxy Surface Plate when the car is on the scales; however, for off scale working the plate should have an additional 2 feet or more of length added to the front. This would have made the plate shown to the right 12’ x 22’ and the nose of the car would still be on the plate for needed measurements, etc.

 

 

 

 

 

 


 

Epoxy Surface Plate Installation

with Scales Flush in Plate

 

    The following is a normal Scales Flush in Plate installation. The recessed areas for the scales should be at least ½ to ¾ of inch deeper than the height of the scale pads at the thinnest point within the recessed area. The epoxy will correct any and all irregularities in the substrate surface. The recessed areas can either be fabricated into the substrate by the concrete contractor when the floor is poured or for existing floors, a concrete contractor is employed to saw cut and removed the existing concrete. If the removal of the existing concrete is down to or below grade level, then a concrete footer may need to be installed to support the epoxy scale platform and scale pad at each of the four recessed areas. The scale pads will support the entire weight of the vehicle making the recessed areas a crucial point for proper substrate strength. All other detailing and reconstruction of removed concrete will be performed by Precision Epoxy.

 

1) The concrete contractor has saw cut the desired lay-out and jack hammered to remove the necessary concrete floor area for the scale pad recess areas and the runs for the connection cables. This is very noisy and messy work and having a concrete contractor that understands the nature of this work is well worth the investment.

 

 

 

 

    It should also be noted that for normal concrete removal, saw cuts will be made in the corners well past the ‘L’ so that the bottom of the saw blade cuts through to the point of the 90° angle for easier concrete removal. The remaining concrete floor will treat the saw cut past the ‘L’ as an expansion joint and will develop a crack that will continue across the substrate to the adjoining recess area. To eliminate this problem, make sure your concrete contractor stops each saw cut exactly at the corner of the ’L’ on the top surface of the substrate. The corners of the recessed areas will then need to be hand chiseled to detail. The chipping of the remaining substrate at edges is not a big deal but should be minimized as much as possible.

 

 

 

 

 


 

 

 

2) Now we remove the existing floor coating within the plate area and prepare the substrate. Mount the temporary aluminum retaining walls at the plate perimeter. Install the tubing for the cable runs and reconstruct the cable runs with the Santex and Slurry Coat Systems.

 

 

 

 

 

3) The anchor bolts are installed and the FP-100 primer coat is applied. These aspects are a part of all our Epoxy Surface Plate installations as described in the Epoxy Surface Plate Installation Procedures Section.

 

 

 

 

 

4) The scale pad recessed areas receive a special custom form work to retain the initial pours of the FP-85 Floor Plate Epoxy.

 

 

 

 

 

 


 

5) The cable run cut-outs and existing expansion joint in the substrate received the IG-100 Fiberglass System to minimize the telegraphing of the cold joints and expansion joint back through the epoxy plate. Note the black material around the form work at the recessed area. That is our SG-25 Structural Gel Epoxy used to reconstruct the chipped out concrete and to reshape the corner for a positive seal at the form to retain the base coat pour of FP-85 Epoxy.

 

6) The Base Coat of Floor Plate Epoxy is poured as described in the Plate Installation Section and allowed to cure. It is then determined that the plate is level within tolerances to proceed to the next steps of the installation process. The base coat is prepared, The recessed area forms are removed, the ‘L’ angle permanent retaining strips are mounted at the recessed area perimeters. The initial reconstruction of the recess area bottom is made and the base coat of floor plate epoxy is poured to level the floor of the recessed areas. The vertical walls of the recessed areas receive their finish coat of SG-25 Epoxy. The Grounding System grid work is installed. Notice the brown material in the cable channel outside the plate area. This is the first application of our Santex System used to fill and reconstruct the channel. Once the entire area is reconstructed, the original floor coating can be reapplied to match the existing floor adjoining these areas.

 

 

 

 


 

 

 

 

7) Now we are ready for the Color Coat of Floor Plate Epoxy. The plate in the foreground has had the color coat poured while the plate in the background has not.

 

 

 

 

 

8) The color coats are allowed to cure and we make our ¼ ” deep saw cut at the outer perimeter of the access ramp using the temporary form work as a saw guide. Then the temporary retaining walls are removed and the perminant Zinc strip retaining walls are installed at the plate’s outer perimeter. All remaining existing floor covering within the ramp area is detailed and removed as needed for proper bonding of the access ramp.

 

 

 

 

9) The grounding rod is installed through the on-grade concrete substrate and the Grounding System is completed as described in the ‘Advanced Grounding System’ section. Now we are ready for the next steps in our installation.

 

 

 

 

 

 


 

 

10) The next step is to bring the scale pad recessed areas to the desired height for the scales to be flush in the plate. This is accomplished with a special jig and process designed by Precision Epoxy that measures and marks the difference between the surface plate plane and the level plane of the recessed area floor. The scales to be used in the plate determine the size and depth of the recessed areas. The most common electronic scale pads are 15”x15“x 2½ ” or 15“x 15“x 4“. Other sizes are also available on the market, so a recessed area that can accommodate the different size ranges will prove more useful in the future as your needs and the scale technology changes.

The floor of each recess area is poured individually and will be perfectly level. The only way to pour them at the same exact height to each other is if they were connected so that all could be poured with the same epoxy pour that flowed from one recessed area to the next. Since this is not the case in our application what we do is get each of the 4 recessed areas to within 60 mills of the desired height below the surface plate plane. It will be up to you to shim your scale pads with flat stock steel or aluminum to have the scales flush in the plate and even with each other to suit your needs. This will also allow for corrections needed for any irregularities between the machining of and the actual height between each individual scale pad which can vary as much as 0.005 inch.

 

 

 

11) The final Santex application is made to reconstruct the cable channel outside of the plate area. The cable tubes are cut flush to the floor and the Santex is sealed. The floor coating is applied to match the existing floor coating adjoining the channel reconstruction. The scale pad cables are routed through the cable tubes and connected to the read out unit at the work station.

 

 

 

 

 

 

12) The access ramp is hand troweled into place, any decal graphics are installed, and the final clear coat of FP-80 Floor Plate Epoxy is poured. The clear coat is allowed to cure and the access ramp is sealed. The final pour is made in the scale pad recessed areas, a final detailing of the entire project is made and the Epoxy Surface Plate with scales flush in the plate is complete.

 

 

 

 

 


 

    The completed installation is allowed one week to fully cure and reach its full hardness of 13,500 psi before its ready to be put into operation. The Epoxy Surface Plate can be cleaned as you would clean any floor area in your shop. For detail cleaning, use plastic cleaners that are non-abrasive and offer anti-static and scratch resistance. The plate will show scratches over a period of time. Avoid dragging heavy and/or sharp objects over the plate surface. Plastic or rubber feet for jack stands and plastic, nylon or rubber wheels for jacks used on the plate will minimize scratching. Scratching of the plate is only cosmetic and will not affect its primary use as a set-up tool.

 

   

 

    Professional 'Turn-Key' Installations generally run between $125.00 to $195.00 per square foot. Sub strate preparation, location of job-site, size of project, depth of scale recessed areas in substrate, travel and/or freight cost, special equipment needed, unusual factors associated with project, etc. all contribute to the pricing of professional applications. The application procedures described are for an average installation scenario. Some projects may require variations from the outlined application techniques herein due to the condition of the substrate, location of job site, size of the project, shape of the completed surface plate, designs and/or artwork in the finish, special equipment needed, any unusual factors associated with the project, etc. Please note: Precision Epoxy only offers this type floor surface plate as a professional installation by Rock Art, Ltd. Some proprietary information has been deliberately omitted from this installation paper. No one is authorized as a contractor to represent themselves as able to install this type flooring as offered by Precision Epoxy Products and Rock Art, Ltd.

 



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Copyright 1970 - 2016 / Rock Art, Ltd.

Precision Epoxy Products
4279 Midway Drive
Douglasville, Georgia 30134
Mike Ramy
(770) 489-0340
mramy@netzero.net

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