protective coatings & linings · pdf file– structural-1/2”- 4 ... owners...
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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
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
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
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
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 !
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
What is Spraywall?
• Spray applied polyurethane
• Rigid
• Quick Curing
– 10 second gel time
– Reinstate flow in 30-60 minutes
• Monolithic finish
Sprayroq Inc. 38
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
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
Sprayroq Inc. 41
Other WastewaterRehabilitation Applications
– Wet Wells
– Lift Stations
– Vaults
– Grit chambers
– Pipelines (Man entry)
– Tunnels
– Sedimentation tanks
– Secondary Containment
Sprayroq Inc. 42
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
Sprayroq Inc. 43
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
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
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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