Case Studies 76,000-Seat NFL Venue, 2.5-Day Window

Mile High Stadium

Location: Denver, Colorado
Project: Indoor Food and Beverage Areas, VIP Club Level
Client: Denver Broncos

Mile High Stadium, officially Sports Authority Field at Mile High, seats over 76,000 for NFL games and is home to the Denver Broncos. It opened in 2001, replacing the original 1948 stadium on a different site, and has sold out every home game since.

After 15 years, the epoxy coating in the indoor food and beverage areas was failing. Replacing it meant working around a stadium that never really stops, inside a fixed 2.5-day window, ahead of a major event.

2.5 days Fixed Completion Window
76,000 Stadium Capacity
24 hrs To Full Cure

The Challenge

A Failing Coating That Could Not Be Patched

After 15 years, the original epoxy coating had been failing continuously for the previous five. Several patch repairs had been attempted, but conventional epoxy has a short re-coat window, so the patches would never re-bond to the original coating.

The badly deteriorated areas were indoor food and beverage spaces, which made the replacement both time sensitive and a hygiene concern. Frequent cleaning is hard on conventional coatings, which tend to micro-crack quickly in demanding conditions.

The client also made it clear that the Broncos preferred green and sustainable materials wherever possible.

On top of that, downtime had to be minimized ahead of a major event that generates substantial food and beverage income. The work could not disrupt employees in the affected area, and it could have no impact on events at all. The client set a fixed 2.5-day completion window.

The Approach

Double the Adhesion, Repairable for Life

Lifetime Green Coatings met every one of the client's sustainability requirements, with a track record on public and private concrete structures stretching back more than 20 years and proven performance in high-traffic public areas.

The coating has roughly double the adhesion on concrete compared with conventional epoxy, and it can be repaired for its entire lifetime because it re-bonds completely to existing Lifetime Green Coatings with perfect adhesion, given normal surface preparation. That directly solved the patching problem that had defeated the previous coating.

It is also completely non-toxic, made from vegetable oil and naturally occurring gypsum.

Its ANSI/NSF-61 rating for contact with potable water was particularly appealing to the client given that the project covered food and beverage areas.

Why It Works

Strip, Degrease, Recoat, Hand Over

Major surface preparation came first, including degreasing years of food and beverage residue. The old failing coating had to be removed completely, and the surfaces left dry and absolutely clean.

The restricted window demanded careful planning and execution. The stadium hosts events constantly, and finishing late was not an option: the VIP Club level generates hundreds of thousands of dollars per day in sales.

The team used the manually applied version of Lifetime Green Coatings. It mixes easily before application and, applied by hand, needs only modest skill levels and standard safety protection for eyes, exposed skin, and breathing.

Because the product contains no Volatile Organic Compounds and sets quickly, disruption stayed minimal throughout.

Tensile Strength	ASTM D412 — 6,000 psi
Compressive Strength	ASTM D695 — 9,400 psi (13,800 psi with quartz)
Elongation	ASTM D412 — 120%
Tear Strength	ASTM D2240 — 330 PLI
Hardness	ASTM D2240 — Shore D 78
Flexibility (1/8" Mandrel)	ASTM D1737 — Pass
Abrasion Resistance (Taber)	ASTM D4060 — 28 mg loss
Gloss	ASTM D523 — 90+
Adhesion (Concrete)	ASTM D4541 — >400 psi (concrete failure), >550 psi primed
Adhesion (Steel)	ASTM D4541 — >2,000 psi
UV Stability	100% UV stable, interior and exterior
Application Temperature	-20°F to 120°F (-29°C to 49°C)
VOC Content	<10 g/l
Food Contact	USDA / FDA certified safe for incidental food contact

Lifetime Green Coatings is engineered for long-lasting performance, with independently tested results across the specifications above.

The Results

Completed On Schedule, Handed Over in 24 Hours

The coating work was completed inside the 2.5-day window. The surface cured within 24 hours, and final inspection at that point allowed for immediate handover.

The project demonstrated again that a high performance material can be genuinely green and sustainable while costing considerably less than conventional epoxy, with no sacrifice in performance and, in practice, superior long-life integrity.

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Mile High Stadium

A Failing Coating That Could Not Be Patched

Double the Adhesion, Repairable for Life

Strip, Degrease, Recoat, Hand Over

Performance Data

Completed On Schedule, Handed Over in 24 Hours