Assets Delivery Group Engineering APPLICATION …...CIA Concrete Institute of Australia CIP Coating...

Assets Delivery Group

Engineering

APPLICATION OF CHEMICAL RESISTANT PROTECTIVE COATING ON

CONCRETE BUNDS IN WATER AND WASTEWATER TREATMENT PLANTS

SPECIFICATION: CR5 ISSUE: 2 DATE: AUGUST 2018

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1.0 SCOPE

This document summarises the procedure for the application of a 2 pack chemical resistant

Novolac Epoxy coating on concrete chemical bunds.

2.0 PURPOSE

The purpose of this coating specification is to prepare a concrete substrate for the application of a

chemical resistance coating.

3.0 DEFINITIONS

ACA Australian Corrosion Association

APAS Australian Paint Approval Scheme

CIA Concrete Institute of Australia

CIP Coating Inspector Program

Contractor The service provider or its sub-contractor who will undertake the works

Corporation The Water Corporation and the Principal for the purposes of externally

contracted asset delivery

ITP Detailed Inspection and Test Plan(s) for the Works

ITR Detailed Inspection and Test Record(s) for the Works

NACE National Association of Corrosion Engineers

PCCP Painting Contractors Certification Program

SSPC Society for Protective Coatings

Superintendent Superintendent for the contract, as defined in the conditions of contract,

who is appointed by the Water Corporation to manage/oversee the work

under the contract on behalf of the Water Corporation

Works The surface preparation, coating application and inspection to be

undertaken by the contractor to which this coating specification applies


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4.0 GENERAL

4.1 Work shall only be carried out by competent personnel.

4.2 The work shall be undertaken by a coating contractor accredited by the PCCP to a class

appropriate for the work to be undertaken.

4.3 The Applicator’s Coating Supervisor shall possess as a minimum one of the following

certifications:

ACA - Coating Inspector; or

NACE - CIP Level II Coating Inspector.

4.4 The coating contractor shall nominate a Coating Inspector as their Quality Control

Officer to carry out inspections, submit the ITP, undertake the required testing and

maintain appropriate records for all work performed.

The Applicator’s Coating Inspector shall possess as a minimum one of the following

certifications:

ACA - Coating Inspector; or

NACE - CIP Level II Coating Inspector.

5.0 SURFACE PREPARATION

5.1 The substrate shall be sound, dry, free from dust/dirt and any surface defects and

contaminants (e.g. oil, grease, salts, chemicals, paint, formwork release and curing

membranes) that may be detrimental to the coating adhesion to the substrate.

5.2 Reference shall be made to SSPC-SP13/NACE 6 “Standard on Surface Preparation of

Concrete Structures” and the coating manufacturer’s standard requirements for the

coating to be applied.

5.3 Principal Representative along with the contractor shall identify and document areas that

contain cracks (> 0.3mm), spalling, rebar corrosion and drumminess and record in the

ITR. Contractor shall repair the defective surfaces in accordance with the construction

supplier’s technical data sheet prior to the application of coating.

5.4 Floor to wall joints, sharp corners etc. shall be “coved” prior to the coating application.

[Refer: Figure 1].

5.5 If needed, spray apply moisture tolerant penetrating surface binding epoxy coat to

strengthen and seal concrete surfaces and allow to harden.


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5.6 Where expansion joints are noted, remove joint material and terminate coating into the

joint prior to reinstating a chemical resistant sealant. Sides of joint to be re-abraded and

primed prior to injecting the new sealant.

Figure 1 – Coving on the floor to wall joint.

6.0 ATMOSPHERIC CONDITIONS

6.1 Prior to and during coating application, the contractor shall record details pertaining to

environmental conditions including ambient and surface temperature, relative humidity

and dew point.

7.0 COATING MATERIALS 7.1 Where a suitable Australian Paint Approval Scheme (APAS) approved product is

available it shall be used. If a suitable APAS approved product is not available, then an

equivalent non-APAS approved product may be used subject to approval by the

Corporation.

7.2 The coating components shall be thoroughly mixed in the specified proportions. Material

so prepared shall be used within the “pot-life” period claimed by the manufacturer for the

relevant site conditions.

7.3 Coating specifications inclusive of datasheets, coating application, method statements and

ITP’s shall be submitted to the Principal for approval at least 10 working days prior to

commencement of the work.

7.4 Recommended drying times between coats for on-site conditions shall not be exceeded.

Coving


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7.5 Applied coatings shall be protected from rain or moisture until cured.

8.0 COATING TYPE & THICKNESS

8.1 Brush apply two or more coats of chemical resistant Novolac Epoxy to produce 500

microns minimum dry film thickness [Refer: Figures 2 & 3].

8.2 For areas requiring a trafficable non-skid surface, broadcast silica/calcined Alumina of

100 mesh directly onto the trowel coat.

Note: Ensure the broadcasted particle do not pierce through the coating.

8.3 Refer Section 15.0 commonly used chemical resistant coatings for concrete bunds in

water & wastewater treatment plants. Select relevant coating system based on the type of

chemical stored in the concrete bund.

9.0 INSPECTION AND TESTING OF COATING

9.1 Visual Testing - Coatings shall be visually examined for surface defects and any

discontinuity arising after curing shall be recorded.

9.2 Spark Testing - The finished coating shall be holiday tested in accordance with NACE

Standard SP0188 – Discontinuity (Holiday) Testing of New Protective Coatings on

Conductive Substrates.

9.3 Adhesion Testing - This test shall be conducted in accordance with AS/NZS 1580

Method 408.5 to determine the adhesion strength of the coating to the substrate.

Reference shall also be made to ASTM Standard D4541, ASTM D7234 and ASTM

C1583/C1583M [Refer: Figure 4].

9.3.1 The minimum acceptable adhesion value for elastomeric coatings on concrete shall be in

accordance with the Section X1.1.1.4 of ASTM D7234 standard.

9.3.2 The location of test sites shall be identified and agreed upon by both the Contractor and

the Principal prior to the start of attaching the dollies to the substrate.

9.4 Coating Thickness Testing – Coating DFT shall be tested using concrete coating

thickness gauge [Refer: Figure 5].

9.5 The results of all testing shall be submitted to the Superintendent at the completion of

work.


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Figure 2 – Full coating on the internals of

the concrete wall.

Figure 3 – Termination of coating on the

outside of the concrete wall.

Figure 4 – Pull-off test on the test panel

[outside of the bund].

Figure 5 – DFT inspection using Positector®

200 gauge.

10.0 REPAIR OF A DEFECTIVE COATING AND RETESTING

10.1 Coatings with defective areas equal to 20% or more of the total coated surface will be

rejected outright.

10.2 Defects such as pinholes, cracks, blisters, voids, foreign inclusions and irregular profile

peaks shall be marked for repair and retested upon full cure of the repaired coating.


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11.0 RECORDING AND REPORTING

11.1 Following testing a report shall be submitted by the Contractor. The Contractor shall

keep detailed records and reports including the following:

Environmental conditions (relative humidity, dew point etc.);

Surface preparation;

Surface profile;

Coating application;

Coating testing; and

General failure.

12.0 COATING FINISH

12.1 The finished coating shall be of uniform thickness, colour, appearance and gloss. It shall

be fully cured, adherent, coherent and free from holidays, laps, sags, blistering, checking,

wrinkling, overspray, patchiness and any other defects that may impair the performance

and/or appearance of the coating.

13.0 INSPECTION

13.1 The Contractor shall maintain records and evidence of the original surface, blast surface

and blast profile. These shall be made available to the Superintendent and/or delegate at

the completion of the project. Evidence of these parameters shall be provided by means

of photographic evidence.

13.2 The Contractor shall provide the Superintendent (or nominated delegate) adequate prior

notice as to when and where the surface preparation and coating operations will be

conducted to facilitate all specified inspections.

13.3 If recognised as a hold point in the ITP, the coating application shall not be carried out

until the Superintendent has accepted the surface preparation.

14.0 CONTRACTOR'S RESPONSIBILITY

14.1 The Contractor shall supply all necessary plant, equipment, materials and labour, prepare

the surface and apply and maintain the protective coating in accordance with this

specification and the coating manufacturer’s requirements.

14.2 The preceding inspection clauses shall not relieve the Contractor of their responsibility to

supply materials and perform work in accordance with the requirements of any overriding

contract documentation.


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15.0 Commonly Used Chemical Resistant Coatings for Concrete Bunds in Water & Wastewater Treatment Plants

Chemical Name Epigen Sika Parchem BASF Epimax SIM Chesterton

Alum. Sulphate - Alum [25%] Chemproof 4029 Sikagard 63N Nitocote EP410 + Durafloor N Ucrete 333AR

Chemclad SC

Chemclad XC

CS4

NVE

Aluminium Chloride

Hydroxide [23-30%]

Chemproof 4029 Sikagard 62 Nitocote EP410 + Durafloor N Ucrete 333AR

Chemclad SC

Chemclad XC

CS4

NVE

Anhydrous Ammonia Chemproof 4029 Sikagard 62 Nitocote EP410 + Durafloor N Ucrete ---

Chemclad SC

Chemclad XC

CS4

NVE

Citric Acid [90%] Chemproof 4029 Sikagard 63N Nitocote EP410 + Durafloor N Ucrete 333AR Chemclad XC NVE

Chlorine Chemproof 4029 Sikagard 62 Nitocote EP410 + Durafloor N Ucrete ---

Chemclad SC

Chemclad XC NVE

Ferric Sulphate [45%] Chemproof 4029 Sikagard 63N Nitocote EP410 + Durafloor N Ucrete 333AR Chemclad XC

CS4

NVE

Fluorosilicic Acid Chemproof 4029 Sikagard 63N Durafloor N short term contact Ucrete --- Chemclad XC NVE

Hydrochloric Acid [26%] Chemproof 4029 Sikagard 63N Nitocote EP410 + Durafloor N Ucrete 421HAR Chemclad XC

988

NVE

Magnesium Hydroxide Liquid Chemproof 4029 Sikagard 62

Sikagard 63N Nitocote EP410 + Durafloor N Ucrete ---

Chemclad SC

Chemclad XC NVE

Magnesium Hydroxide Chemproof 4029 Sikagard 62


Chemclad SC

Chemclad XC NVE

Potassium Permanganate Chemproof 4029 Sikagard 62

Sikagard 63N Nitocote EP410 + Durafloor N Ucrete 421HAR

Chemclad SC

Chemclad XC

CS4

NVE

Sodium Hydroxide

[Caustic Soda 50%]

Chemproof 4029 Sikagard 62

Sikagard 63N Nitocote EP410 + Durafloor N Ucrete 333AR

Chemclad SC

Chemclad XC

CS4

NVE

Sulphuric Acid [98%] Chemproof 4029 Sikagard 63N Durafloor N short term contact Ucrete 421HAR Chemclad XC

CS4

988

Sodium Bisulphite [35-40%] Chemproof 4029 Sikagard 63N Nitocote EP410 + Durafloor N Ucrete 333AR

Chemclad SC

Chemclad XC

CS4

NVE

Sodium Hypochlorite [12.5%] Chemproof 4029 Sikagard 62

Sikagard 63N Nitocote EP410 + Durafloor N Ucrete 333AR Chemclad XC NVE

Sod.Metabisulphite [35 - 40%] Chemproof 4029 Sikagard 62


Chemclad SC

Chemclad XC

CS4

NVE

Note:

If there is an acid spill in the coated bund area, the spillage shall be cleaned within 48 hours.

Where a coating system requires more than one product to be used (e.g. Primer and top coat) both product shall be from the same supplier unless approved otherwise by the Senior Engineer, Corrosion Control

Section.

The Water Corporation cannot be held responsible for the claims or performance guarantees offered by construction product suppliers.

Due to continuous product development, coating contractors shall check with product suppliers to confirm that the product names and numbers are current at the time of ordering.


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16.0 INSPECTION AND TEST PLAN [SAMPLE]

CLIENT WATER CORP LOCATION Chlorine Building ACTIVITY CC5 – EPIGEN EPOXY APPLICATION

ITEM ACTIVITY DESCRIPTION TEST TYPE FREQ. OF TEST INSPECTED BY APPROVED BY ACCEPTANCE CRITERIA

CODE / SPEC

1 Cut delineations to all horizontal and

vertical terminations

Measurement and

visual

On completion PCS / Client SS WC Cut to be 5 x 5mm around all cast in items and floor

joints

2 Surface preparation – 5000 psi

pressure water cleaning

Visual inspection

of cleaned surface

Ongoing and on

completion

PCS / Client SS WC All surface contamination and dusting removed,

Section 5.1, 10.3 & 10.4

2

Surface patching – Epigen 4040 Visual inspection

of repaired

surfaces

On completion PCS / Client SS WC Large surface imperfections removed, Section 5.1 and

Manufacturers specification

3

Coating application – Epigen 4040 &

4029 Topcoat as per Method

Statement Supplied

Visual inspection

of coating

application

100% of surface after

each coat

PCS / Client SS HC Section 10.3 and Manufacturers specification

5

Film thickness Non-Destructive

DFT testing

On completion,

minimum 6 test per

building

PCS / Client SS HC Thickness Appendix 2 CC5, Manufacturers

specification

6

Coating Discontinuity (Holiday)

Testing

Spark Testing 100% of surface on

completion

PCS / Client SS HC Section 10.8

LEGEND DESCRIPTION Form No. Rev No. Amendment Date Approved

SS Initial by PCS Site Supervisor QC Prepared By S Power 01 7/11/2011

WC Witness. Initial by Client QA - QC Manager Client Approval P Dumitra 01 8/11/2011

HC Hold. Initial by Client QA - QC Manager Client Approval

PLEASE NOTE: If any items has not been initialed or signed off by either party it will be classed as a non-conformance and the consequences are to be met or the item will remain as a non-conforming item.

Any non-conforming items may void the application warranty

COMMENTS:

--End of Document---


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CONCRETE CONDITION ASSESSMENT SURVEY FORM

CONCRETE SURVEY FORM: SF ISSUE: 2 DATE: AUGUST 2018

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Surface Condition

Honeycombing

Yes

No

If yes, Approximate % area ______________

Bleeding

Yes

No

If yes, Is it mild? or severe?

Pop-outs

Yes

No

If yes, big lumps? Or small?

Voids

Yes

No

If yes, diameter? ______________mm

Early Cracking

Voids

Yes

No

Comments:

_________________________________________

Date: Asset Deficiency

Report [ADR] No.

Inspected

By:

Asset

Location:

SWR NWR GPS Co-Ordinates

GSR MWR Easting:

GAR PM Northing:

Functional Location:

Years in Service:

Asset Type:


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Concrete Quality

Surface

hardness/Strength

Min Value _________________________________________ MPa

Max Value _________________________________________ MPa

Compliance to AS/NZS 3735: Waste Water Potable Water

Rebar Cover

Concrete Cover

Min Cover _________________________________________mm

Max Cover _________________________________________mm

Compliance to AS/NZS 3735: Waste Water Potable Water

Mechanical

breakout

Yes

No

Structural effects

Overloading

Yes

No

Dynamic Effects

Yes

No

Structural

Cracking

Yes

No

Surface damage

Chemical attack

Yes

No

Comments:

_________________________________________

Abrasion

Yes

No

Comments:

_________________________________________

Leaching

Yes

No

Comments:

_________________________________________


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Spalling

Yes

No

Comments:

_________________________________________

Staining

Rebar corrosion

Yes

No

Comments:

_________________________________________

Efflorescence

Yes

No

Comments:

_________________________________________

Salts

Yes

No

Comments:

_________________________________________

Cracking

Width Yes No

Less than 0.2 mm

Comments:

_________________________________________

0.2 mm to 1.0 mm

Comments:

_________________________________________

Greater than 1.0

mm

Comments:

_________________________________________


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Rebar condition

Visual examination of

bar

Yes

No

Comments:

____________________________________

Rust

Yes

No

Comments:

____________________________________

Pitting damage

Yes

No

Comments:

____________________________________

Carbonation

Indicator test on cores

Yes

No

Comments:

___________________________________

Mechanical breakouts

Yes

No

Comments:_________________________

Delamination

Size

Yes

No

Comments: ___________________________

Frequency

Yes

No

Comments:

____________________________________

Severity of delamination

Yes

No

Comments:___________________________

Previous Repairs

Integrity of repairs

Yes

No

Comments: __________________________

Signs of damage near

repair locations

Yes

No

Comments: __________________________

--- End of Document ---

Assets Delivery Group Engineering APPLICATION …...CIA Concrete Institute of Australia CIP Coating...

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