An Unforgettable Experience: Coating 11 SKIES Parking Facility in Hong Kong

To tackle a job of this size, it was critical to divide the space into zones with specific teams assigned to each distinct area. “We had to meticulously organize our teams and establish clear zoning strategies,” Kwong explained. “Breaking down the massive area into manageable sections was crucial for optimizing efficiency and coordination. Each team was assigned specific zones to work on, which required precise delineation and ongoing communication to avoid overlaps or confusion. We had to emphasize the importance of sticking to designated areas to ensure a smooth workflow and prevent any disruptions.”

Each of the three zones was manned by a crew of 10 or more, and depending on the task at hand, there were up to 40 team members working onsite at any given time. The structured zoning approach not only allowed the crew to streamline operations and maintain high standards of quality across the project, but also to complete the project within the tight three-month timeframe.

However, according to Kwong, adhering to the tight timeline was complicated by several factors, including the presence of other trades prior to surface preparation and coating application, weather conditions, and quality assurance at various stages of the job. “Throughout the project, we navigated shared spaces and resources and worked around other trades,” Kwong said. “We had to wait for floor locations to [be] cleared before we could begin our portion of the work. Effective project management and communication were crucial in addressing these challenges to maintain progress.

“In addition, coatings have specific curing times, and environmental factors like temperature and humidity played a [large] role in the application process,” Kwong added. “We had to meticulously develop a detailed project schedule that accounted for drying and curing times while also accommodating potential delays.”

Kwong was also quick to point out that to ensure consistent quality throughout the 124,000-m2 parking facility, there were many quality assurance measures in place, such as sample checking, coordination between working zones to ensure the quality of junction areas between phases, and compliance with the line marking dimensions and locations mandated by the Hong Kong Buildings Department. “We conducted thorough evaluations of the onsite final product, focusing on critical elements such as color, texture, and thickness to ensure they met project specifications,” said Kwong. “Discrepancies necessitated additional time for re-evaluation and adjustments.”

With all logistical strategies and plans in place, the team was ready to begin the surface preparation process. While the parking facility was a new build, there were still some minor concrete defects that needed to be addressed. “Despite the overall good condition of the substrate, we did come across some small cracks, surface imperfections, or areas with slight degradation,” Kwong said. “Although these issues were relatively minor, they still required attention and preparation work before applying the coating.”

According to Kwong, the surface preparation process involved steps such as crack repair, surface cleaning, and, when necessary, surface grinding or patching to achieve a level and uniform substrate. By addressing these defects, the team was able to create an optimal surface for the subsequent coating application.

For areas that needed concrete repair or patching, high-pressure air tools were used to clean the cracks, as well as specially designed grinding machines. “These machines enable precise surface preparation, ensuring that any uneven areas are effectively leveled and smoothed out,” Kwong said. “For the patching process, we [used] Flowcrete Flowtex F1 Repair Mortar. This material is known for its excellent adhesion and durability, making it ideal for repairing concrete surfaces in high-traffic areas like 11 SKIES. The resinous mortar not only fills cracks and imperfections, but it also contributes to the overall longevity and resilience of the concrete, ensuring it can withstand the demands of a busy car park environment.”

Flowtex is known for its superior bonding properties and flexibility, helping to ensure that the repairs not only fill the cracks but also adapt to any future movement in the substrate, maintaining the integrity of the surface.

In addition to crack repair and patching, the entire concrete floor of the parking facility was shot blasted and cleaned using an air spray gun. The shot-blasting process removed contaminants and created a roughened profile on the concrete surface, ensuring optimal adhesion for the Flowcrete Deckshield ID system. Once the shot-blasting process was completed, the crew used air spray guns to blow away any dust and debris from the entire area.

“Thorough cleaning of the entire surface is essential in preparing the substrate for the subsequent coating applications, ensuring durability and longevity in our work,” said Kwong.

With the concrete substrate properly prepared, the crew was ready to shift to the next step: the application of the Flowcrete Deckshield ID system. However, there were many factors to consider prior to the coating system application. Constant monitoring of the ambient temperature and humidity was necessary for the proper adhesion and curing of the coating system.

“Lower temperatures extended the chemical curing times, requiring additional time for the materials to set properly,” Kwong explained. “These conditions did lead to some delays in the project timeline because we had to ensure that the coatings fully cured to achieve optimal performance and durability. However, the overall timeline was not affected, and we handed over the project on time to the landlord.”

According to Kwong, the crew also had to monitor the moisture within the concrete substrate itself. “One major issue [we had during the project] was the underground physical water [rising]. This condition posed a risk of damaging the coating system because excess moisture could compromise the integrity and performance of the applied materials. We had to implement careful monitoring and management strategies to mitigate this risk and ensure the longevity of the coating.”

In addition to dealing with various temperature and moisture challenges, the crew also needed to ensure that all aspects of the job complied with Hong Kong’s stringent environmental laws and regulations. This included adherence to permissible volatile organic compound (VOC) levels during the coating application and proper waste management practices.

“VOC emissions from coatings can have adverse effects on air quality and the environment. To mitigate this, we chose low-VOC coatings brand Flowcrete that complied with local regulations,” Kwong said. “This decision helped minimize our project’s impact on air quality while maintaining high-quality results.”

The team also made sure to handle and dispose of chemicals responsibly, following manufacturer recommendations and local regulations.

Overall, safety was always a top priority for the Kwong Man Kee Engineering Limited crew. Thorough safety assessments were conducted to identify potential hazards and dangerous conditions, comprehensive safety measures were implemented, and proper personal protective equipment (PPE) such as face masks, safety goggles, and work shoes were worn. The team also conducted regular safety training sessions to ensure the well-being of everyone on the jobsite.

According to Kwong, there were many compelling reasons why the Flowcrete Deckshield ID coating system was chosen for the 11 SKIES parking facility project. “The surface is designed for easy cleaning and maintenance, ensuring long-term durability and performance. It also has excellent anti-slip functions that enhance safety for vehicles and pedestrians, making it an ideal choice for high traffic areas. Deckshield ID also contributes to tire noise reduction during use, contributing to a more pleasant environment for visitors and nearby residents.”

As mentioned above, the coating system has low VOCs, supporting both healthier indoor air quality and compliance with environmental regulations. And as a Leadership in Energy and Environmental Design (LEED-) certified product, Deckshield ID aligns with sustainable building practices, contributing to the overall green credentials of the project.

The solvent-free, flexible polyurethane traffic coating system is comprised of four layers: Deckshield SF primer, Deckshield Quartz sand scatter, Deckshield Finish, and Deckshield UV topcoat. “The Deckshield SF primer was applied using specialized hand tools and squeeze tools, ensuring precision and uniform coverage,” said Kwong. “The application thickness typically adhered to the specifications outlined in the product data sheet, which generally recommends a thickness of 200–300 microns [7.9–11.8 mils].”

The crew applied two coats of the primer to achieve optimal adhesion and performance. Each coat was allowed to cure adequately before the subsequent application, ensuring a robust foundation for the subsequent layers of the coating system.

The crew then laid down Deckshield Quartz as the sand scatter. This high-quality quartz not only enhances the aesthetic appeal but also provides improved slip resistance and durability to the surface. For the base coat, the Deckshield Finish was applied using specialized hand tools and squeeze tools. This method ensures precision and even coverage across the surface. The typical application thickness is approximately 2 mm (0.08 inch), depending on project specifications. “In our process, multiple coats were applied to enhance durability and performance, ensuring a robust finish suitable for the demands of the car park environment,” Kwong said.

The Deckshield UV was then applied as an additional protective layer, specifically for external areas to prevent over-weathering. The application was carried out using specialized hand tools, ensuring precise and even coverage. “Typically, a single coat was applied at a thickness recommended by the manufacturer to achieve optimal protection and durability,” Kwong said.

Although the 11 SKIES parking facility job was challenging, Kwong is proud of the overall result, especially the fact that the team was able to overcome all obstacles and turn the job over to New World Development Hong Kong on schedule.

“Completing such a large-scale project within a tight timeframe of three months presented significant challenges,” Kwong said. “This required meticulous planning and coordination to ensure that all tasks were executed efficiently. Effective project management was essential to address any unforeseen issues and maintain progress, ensuring that we met our deadlines without compromising quality.”

Kwong is also proud that Kwong Man Kee Engineering Limited actively engaged a significant number of women on the 11 SKIES project. “[These women] made valuable contributions to the project’s success,” she said. “Recognizing the diverse talent pool available, we sought to create an inclusive work environment that encouraged women to participate in construction activities.”