protective coatings & linings 2011 with notes
TRANSCRIPT
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PROTECTIVE COATINGS & LININGSFor
WASTEWATER & WATER STRUCTURES
By
Rocky Capehart
2011
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Accelerated corrosion problems in todaysinfrastructure and a greater awareness ofcorrosion issues, require demanding and
viable long-term solutions.
MIC (Microbiologically Induced Corrosion)Thiobacillus (Bacterium/Bugs) feed on the sulfur within the H2S and excrete
sulfuric acid which then attacks the concrete matrix!
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Corrosion will increase due to: Reduction of inflow and infiltration
Regulatory changes in pre-treatment
Expansion of collection systems
EPA/625/6-91/030
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How Do We Achieve Long TermQuality Coatings & Linings
Performance?
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THIRD PARTY TESTING AND SPECIFICATIONS
RESOURCE PROPERTIESLos Angeles County Sanitation Ease of Application
Chemical ResistanceBond Inspection
Greenbook - City of Los Angeles Chemical ResistanceChange in Physical Properties
Trenchless Technology Center Buckling StrengthHydrostatic Pressure Effects
Independent Testing Labs Permeability(Following ASTM Standards) Tensile/Flexural/Compressive Properties
Chemical Resistance
Material Safety Data Sheets Safety & Handling
Others: NACE (National Association of Corrosion Engineers), SSPC(The Society for Protective Coatings), ICRI (International Concrete RepairInstitute) and Universities Across North America
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Can Help Prevent:
CORRECT PRODUCT SELECTION,
INSTALLATION & INSPECTION
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Polymer Coating and Liner Disbonding
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Aggressive Corrosion
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Pinholes
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Epoxy FailureThin coating and pinholes
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Inner Coating Delamination & Poor Adhesion
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Thinner Than Required Coating Applications
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Thinner Than Required Coating Applications &Applicator Error
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Roots and Infiltration
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Substrate Failure Behind The Lining
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Equipment / Tool Damage & Pinholes
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WRINKLES & SAGS
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HOW DO WE SELECT THE CORRECT COATINGOR LINING SYSTEM ?
Thermoplastic sheet liners Cementitious systems
Polymer Systems
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STRUCTURAL & NON-STRUCTURALRENEWAL OPTIONS
Cementitious Coatings (Portland to CalciumAluminates')
Structural-1/2- 4 (May require reinforcement)
Non-Structural-3/8-1/2
Polymer Coatings (Epoxies and Polyurethanes)
Structural-125-500 mils (1/8 1/2)
Non-Structural-60 mils minimum-100 milsaverage
Composite Systems
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CORROSION PROTECTIONOPTIONS
Cementitious formulations Calcium aluminate
Antimicrobial additives
Thermoplastic linings
Cement or polymer
mastic basecoat Polymer coatings
Epoxies,polyurethanes,
polyureas
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COATING THICKNES
Profile Height (New surface or Exposed Aggregate)
Effects of hydrostatic head pressure or water vapor transmission
(Design with industry accepted ASTM F1216-07 for StructuralApplications to withstand long term external hydrostatic loadings)
Environment
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UNDERGROUND INSTALLATIONVARIABLES
Temperature and humidity Moisture filled substrates Hydrostatic pressure Water vapor transmission Surface and structure
condition Accessibility and confined
space
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KEY FACTORS FOR PREP SUCCESSObtain a clean, dry and sound surface!
Understand repairprocedures:
Substrate lossor infiltration
Understandpreparationprocedures
Know how to testpreparationresults
Know commonmethods of:
cleaning power
abrasive
choices coating
removal
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COATINGINSPECTION PARAMETERS
SAMPLE FORM Quality Assurance/Quality ControlContract Name: __Manhole Rehabilitation ______________________ ______________ Contract No: _________________________
Contractor/Installer: ___________________________ Construction Observer/Inspector: _____________________________
Report No.__________ Weather:______________________________ Structure Temp: Ambient___________ Surface_____________
Other Work in Progress: ______________________________ _______________________ _______________________ ________________
Inspection
Performance Acceptable Results
No. Quality Assurance Standard Quality Quality Control Pass/Fail Comments
1
Visual inspection of structure
substrate after c leaning and
preparation
Industry
S tandard 100%
Visually inspect surfaces to be coated for
effective removal of existing c oatings, unsound
substr ate, laitance, infiltration. Vis ually identify
problem areas.
2 Test substrate for soundness.
SSPC- SP
13 NA CE
No. 6 100%
Lightly scratch prepared concrete surfaces with a
screwdriver or pocket knife. The scratch should
leave a shiny mark with no loose particles from
the surface. Otherwise, re-prep and re-inspect.
3
Visual inspection of product
application and documentation of
proper material ratio/usage
Product
Technical Data
S he et (r at i o) 1 00 %
Visually observe mixed color which should be
homogenous without marbling effect. Inspection
recordkeeping of applicator for material usage of
product components, verify proper usage.
4
Wet Film Thickness (WFT)
measured during application. NOTE:
When applying fast setting
polyurethanes, this test is not
applicable. Use the adhesion test to
also measure mil thickness. ASTM D-4414
No less
than 90% or
greater than
120%
Measure and record the WFT in at least four
locations for every 500 sf and each coat of
material applied.
5
Holiday Detection using a high
voltage holiday detector.
NACE RPO-
188 100%
Confirm conductivity by inducing holiday and
calib rating detector. Test entire coated surface.Repair and retest as required.
6
Adhesion Testing using a Elcometer
Model 106 on a minimum of 10% of
the manhole structures coated. ASTM D-4541
As
specified
Perform a minimum of three pull tes ts per
manhole at locations randomly selected.
Evaluate results and repair c oating where tested.
Record dolly location, pull
strength (psi), mode of failure
and whether dolly was scored
or unscored.
Owners Representative: Name Signature Date
Contractor/Installer Representative: Name Signature Date
All QA/QC as per specific manufacturer'sr ecommendations.
Substrate inspection - Ambient conditions - Surface profile - Surfacecleanliness Mixing procedures - Application procedures
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IMPROVED QUALITY CONTROL
QA/QC during construction with
Trained Inspectors & Documentation
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QUALIFIED CONTRACTORS
>90% of all failures result from improper installation!
Contractor RequirementsCertification of Training
Manufacturer
Third party
NACE (National Association of Corrosion Engineers)
SSPC (The Society for Protective Coatings)
Experience Similar scope, size or training Actual Field Experience
References
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Established manufacturersthat implement QC duringmanufacturing (ISO 9000)
Suitable for application in
specified environment
Capable of providingprotection and/or structuralneeds
Field tested and proven
Independent and certifiedthird party laboratorytesting
Quality Control - Materials
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EQUIPMENT
Equipment is product
dependent
Some can bemobilized intounderground
structures asnecessary
Efficiency andproduction varies(Brush, roller, troweled
or spray applications)
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VISUAL INSPECTION
Cracking, pinholes, exposedsubstrate
Proper bench and invertrebuild
Frame/chimney sealing
Pipe joint seals
Step removal or replacement
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MONOLITHIC INSTALLATION
Holiday (Spark) Testing
A barrier without fault provides effective long-termelimination of infiltration and corrosion protection
Refer to NACE RPO188-Concrete & SteelRefer to ASTM G627-87-Steel Pipe
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HOLIDAY (SPARK) TESTINGEQUIPMENT
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ADHESIONA verifiably acceptable mechanical bond to the host structure is essential for
long-term performance.USE EXPERIENCED INSPECTORS
FOLLOW ASTM D7234-05 or MODIFIED ASTM D4541-02 STANDARDS
NOTE: ASTM D7234-05 includes cohesion and adhesion test formulas
A CLEAN AND DRY SURFACE
WILL PROVIDE OPTIMAL RESULTS !
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ADHESION (PULL) TESTINGEQUIPMENT
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REMEMBER THE SEVENREMEMBER THE SEVEN PPs!s!Performance Specifications-Tight & With Stringent QA/QC
Proven Products & Correct Selection
Proper Preparation Of Surface & Coating With Certified,Trained & Experienced Applicators
With Use Of The Above Guidelines, You Will Discover That
Perfect Performance For A Longer Term Is Virtually Guaranteed
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The Gold StandardThe Gold StandardSpray AppliedSpray Applied
PolyurethanePolyurethaneForFor
Water and WastewaterWater and Wastewater
Infrastructure RehabilitationInfrastructure Rehabilitation
www.sprayroq.comwww.sprayroq.com
Rocky CapehartRocky Capehart
(916) 686(916) 686--80558055EE--mail: [email protected]: [email protected]
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Sprayroq Inc. 37
What is Spraywall?
NOT AN EPOXY!NOT AN EPOXY!
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What is Spraywall?
Spray applied polyurethane
Rigid
Quick Curing
10 second gel time
Reinstate flow in 30-60 minutes
Monolithic finish
Sprayroq Inc. 38
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Sprayroq Inc. 39
What is Spraywall?
Adapts to all shapes and structures
200,000+ Structures Rehabilitated
NSF 61 Approved
50 year design life
Creep test revealed 70%+ retention of original technicalproperties
Passed the Redner Study (L.A. County)
Passed the Greenbook Pickle Jar Test
Chemical Resistance Tested as per ASTM D543
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Sprayroq Inc. 40
Spraywall Properties
Technical Properties
730,000 psi Flex Modulus(45% stronger than theoriginal concrete structure)
3.8% elongation Tensile 7,450 psi
Compressive Strength>18,000 psi
Pull test yieldsat 450 psi -700 psi
Density 87 pcf
Chemical Resistance
Hydrogen Sulfide
Sulfuric Acid to 20%
Chlorine to 10%
Road salts
Quick Cure
10 seconds to gel
4-6 hrs to full cure
100% VOC free
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Sprayroq Inc. 41
Other WastewaterRehabilitation Applications
Wet Wells
Lift Stations
Vaults
Grit chambers
Pipelines (Man entry)
Tunnels
Sedimentation tanks
Secondary Containment
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Sprayroq Inc. 42
Sprayroq Certified Partners
National network of highly trained, diversified contractors Licensee program started in 1992 with Insituform
Technologies
12 to 1 ratio of acceptance into program
Yearly QA/QC Review
Ongoing Technical and Marketing support
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Sprayroq Inc. 43
Training Class In House
New SCPs crews travel to Birmingham Final installation of equipment
Classroom training Chemistry Basics
Equipment setup and maintenance
Surface Prep and Infiltration Control
Spray technique
Written test
President of Sprayroq authorizes SCP for work
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Sprayroq Inc. 44
Training Class-In the Field
Sprayroq Operations team travels to SCP facilities for oneweek
1-2 days of follow up classroom work
Final equipment inspection completed
Sprayroq Ops co-supervises demo projects or actual work
Fine tuning is completed with each person
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Sprayroq Inc. 45
Third Party Testing
Conducted currently by Texas ResearchInstitute in Austin, TX
Complete test panels
Flex Modulus
Elongation
Tensile strength
Compressive strength
Louisiana Tech U completed study verifyingbursting strength (internal) of Spraywall
St. Louis Testing Laboratories
Chemical Resistance as per ASTM D543
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Sprayroq Inc. 46
SprayWallSprayWallSprayroq Tough!
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The Gold StandardThe Gold Standard
SprayWallSprayWallSpray AppliedSpray Applied
RigidRigid PolyurethanePolyurethane
ForFor
Water and WastewaterWater and WastewaterInfrastructureInfrastructure
RehabilitationRehabilitation