PROTECTIVE COATINGS & LININGSFor

WASTEWATER & WATER STRUCTURES

ByRocky Capehart

2011

Accelerated corrosion problems in today’sinfrastructure 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!

Corrosion will increase due to:

– Reduction of inflow and infiltration

– Regulatory changes in pre-treatment

– Expansion of collection systems

EPA/625/6-91/030

How Do We Achieve Long TermQuality Coatings & Linings

Performance?

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

Can Help Prevent:

CORRECT PRODUCT SELECTION,INSTALLATION & INSPECTION

Polymer Coating and Liner Disbonding

Aggressive Corrosion

Pinholes

Epoxy FailureThin coating and pinholes

Inner Coating Delamination & Poor Adhesion

Thinner Than Required Coating Applications

Thinner Than Required Coating Applications &Applicator Error

Roots and Infiltration

Substrate Failure Behind The Lining

Equipment / Tool Damage & Pinholes

WRINKLES & SAGS

HOW DO WE SELECT THE CORRECT COATINGOR LINING SYSTEM ?

Thermoplastic sheet liners Cementitious systems

Polymer Systems

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

CORROSION PROTECTIONOPTIONS

• Cementitious formulations

– Calcium aluminate

– Antimicrobial additives

• Thermoplastic linings

– Cement or polymermastic basecoat

• Polymer coatings

– Epoxies,polyurethanes,

polyureas

COATING THICKNESS

• 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

UNDERGROUND INSTALLATIONVARIABLES

• Temperature and humidity• Moisture filled substrates• Hydrostatic pressure• Water vapor transmission• Surface and structure

condition• Accessibility and confined

space

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

– abrasivechoices

– coatingremoval

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 cleaning and

preparation

Industry

Standard 100%

Visually inspect surfaces to be coated for

effective removal of existing coatings, unsound

substrate, laitance, infiltration. Visually identify

problem areas.

2 Test substrate for soundness.

SSPC- SP

13 NACE

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

Sheet (ratio) 100%

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

calibrating 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 tests per

manhole at locations randomly selected.

Evaluate results and repair coating 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's recommendations.

Substrate inspection - Ambient conditions - Surface profile - Surfacecleanliness Mixing procedures - Application procedures

IMPROVED QUALITY CONTROL

QA/QC during construction with

Trained Inspectors & Documentation

QUALIFIED CONTRACTORS

>90% of all failures result from improper installation!

Contractor Requirements– Certification 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

• Established manufacturersthat implement QC duringmanufacturing (ISO 9000)

• Suitable for application inspecified environment

• Capable of providingprotection and/or structuralneeds

• Field tested and proven

• Independent and certifiedthird party laboratorytesting

Quality Control - Materials

EQUIPMENT

• Equipment is productdependent

• Some can bemobilized intoundergroundstructures asnecessary

• Efficiency andproduction varies(Brush, roller, troweledor spray applications)

VISUAL INSPECTION

• Cracking, pinholes, exposedsubstrate

• Proper bench and invertrebuild

• Frame/chimney sealing

• Pipe joint seals

• Step removal or replacement

MONOLITHIC INSTALLATIONHoliday (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

HOLIDAY (SPARK) TESTINGEQUIPMENT

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 !

ADHESION (PULL) TESTINGEQUIPMENT

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

The Gold StandardThe Gold StandardSpray AppliedSpray AppliedPolyurethanePolyurethane

ForForWater and WastewaterWater and Wastewater

Infrastructure RehabilitationInfrastructure Rehabilitationwww.sprayroq.comwww.sprayroq.com

Rocky CapehartRocky Capehart(916) 686(916) 686--80558055

EE--mail: rcapehart@sprayroq.commail: rcapehart@sprayroq.com

Sprayroq Inc. 37

What is Spraywall?

NOT AN EPOXY!NOT AN EPOXY!

What is Spraywall?

• Spray applied polyurethane

• Rigid

• Quick Curing

– 10 second gel time

– Reinstate flow in 30-60 minutes

• Monolithic finish

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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

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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Other WastewaterRehabilitation Applications

– Wet Wells

– Lift Stations

– Vaults

– Grit chambers

– Pipelines (Man entry)

– Tunnels

– Sedimentation tanks

– Secondary Containment

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Sprayroq Certified Partners

• National network of highly trained, diversified contractors

• Licensee program started in 1992 with InsituformTechnologies

• 12 to 1 ratio of acceptance into program

• Yearly QA/QC Review

• Ongoing Technical and Marketing support

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Training Class – In House

• New SCP’s 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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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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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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SprayWallSprayWallSprayroq Tough!

The Gold StandardThe Gold Standard

SprayWallSprayWallSpray AppliedSpray Applied

RigidRigid PolyurethanePolyurethaneForFor

Water and WastewaterWater and WastewaterInfrastructureInfrastructureRehabilitationRehabilitation