Tower Constructed from Lightweight Foam and Polyurethane Takes Direct Hit from Three Hurricanes and Survives

Chemthane 7000 is a two component spray polyurethane resin was applied to a 28 foot tall colorful fountain/tower at the Omni Orlando Resort at Champions Gate. Once applied, this product creates a tough, impact resistant shell of protection that resists cracking, warping and water intrusion.

Orlando, FLA.--Situated in the center of Florida, the Omni Orlando Resort at Champions Gate offers a vibrant oasis of sports and leisure to weary travelers. The 1,200 master-planned community was completed in 2004 to rave reviews by guests, industry experts and golf professionals. Little did everyone know, the 2004 hurricane season would put the buildings and construction material to the ultimate test.

The $175 million resort features 36-holes of golf, the David Leadbetter Golf Academy, 730 guest rooms, 70,000 sq. ft of meeting space and a 15 acre leisure area with heated pools and a lazy river winding through it. The unique leisure area features a 28 foot tall colorful fountain/tower that rains down pool water on guests.

?EUR??,,????'??The tower has become the hub of activity at the resort,?EUR??,,????'?? commented Paul Pebbly, spokesperson for Omni Hotels. ?EUR??,,????'??The distinctive tower gives Champions Gate its identity. Since it is a tall structure in the center of the resort complex, guests often use it as the meeting place.?EUR??,,????'??

The huge structure is unique in its construction, too. Exoscope Design & Fabrication, Inc., a central Florida fabricator, built the structure with the skeleton made of steel beams. The outer skin of the tower is lightweight, carved expanded polystyrene foam (EPS) panels. The EPS is coated with Chemthane 7000, a spray applied polyurethane hard coating that adds rigidity and structural stability to the foam. The coating is applied at 3/16?EUR??,,????'?? (5mm) thick. Over the top of the primed polyurethane is applied a Venetian stucco and a UV resistant top coat to protect the finish from the harsh Florida sun and chlorinated water.

During the summer of 2004, this innovative construction method was challenged by the forces of Mother Nature - not just once, but three times in a row. Within a few weeks, three major hurricanes (Charlie, Frances and Jean) roared across Central Florida bringing property damage and destruction in with them. In fact, Hurricane Charlie checked into Champions Gate with a direct hit.

In these conditions, tall structures like the foam tower tend to fall or take serious damage from airborne debris. According to Scott Freeland, President of Exoscope, fabricator of the tower, ?EUR??,,????'??the eye of the hurricane passed right over the tower. Even though it is located in an open area, exposed to winds in excess of 85 mph (Category 4), the tower did not even show surface damage. Other structures in the area were completely destroyed or badly damaged.?EUR??,,????'??

Freeland added: ?EUR??,,????'??The success of this structure is due in large part to the polyurethane hard coating over the EPS. The Chemthane 7000 coating was able to resist damage from impact and high winds under the most extreme conditions.?EUR??,,????'??