Polyurea Coatings in Secondary Containment with National ...

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PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Polyurea Coatings in

Secondary Containment with

National Technical Approval

Jürgen Magner

Kiwa Polymer Institut

Flörsheim / Germany

Polyurea for secondary containment

rack tanks

organic coating

concrete

substrate

secondary containment =

protection in case of accidents

Germany

• § water balance law §

• principle of concern for any kind of

possible ground water pollution

• principle of best possible protection for the

soil – ground water

Secondary containment based on concrete

• Design with reinforcement and maximal

crack width of the concrete of 0,2 mm

• If possible: no joints

• Concrete is not dense and allows the

passage of ground water / soil

contaminating liquids

Requirement for organic coatings

• Crack bridging (> 0,2 mm)

• Adhesion

• Resistance to external exposure (freeze, UV)

• Chemical resistance

• Electrostatical discharge behaviour

• No existing national norm

• No European Norm

• No European Technical Approval Guideline

• National approval guidelines for sumps,

secondary containment and concrete

surfaces in facilities for the storage, filling

and handling of water polluting liquids, Zulassungsgrundsätze für Auffangwannen, Auffangräume und

Flächen aus Beton in Anlagen zum Lagern, Abfüllen und Umschlagen

von wassergefährdenden Flüssigkeiten

• Issuer:

DIBT- German Institute for Construction

Technique Deutsches Institut für Bautechnik

• Successful story since the middle of the 80s

• More than 350 approvals

• Chemical resistance

test procedure and list of more than 15

main chemical classes has even lead to

EN 13529

Chemical resistance

EN 13529

Products and systems for the protection and repair of concrete

structures - Test methods - Resistance to severe chemical attack

Liquid class 1-3

Liquid class 4

Liquid class 5 - 8

Liquid class 9 -12

Liquid class 13 - 15

Supplementary liquids or higher concentrations not

systematically included in the list have to be tested

separately

Example

Class 10: sulfuric acid of 20 %

Included: hydrochloric acid of up to 20%

Not included: HCl conc.

1 Fixing plate

2 Compressed air hose

3 Glued rings

4 Concrete slab

5 Chamber

6 Testing liquid

7 Organic coating system

8 Metal frame

Test device for testing of

chemical resistance

Levels and exposures acc. to containment character

Inspection after Exposure

– Blistering

– Flaking

– Cracking

– Optical changes (colour gloss)

– Adhesion, Hardness

– Penetration of chemicals

Chemical class Level for a polyurea system

1 MIDDLE L2

4 MIDDLE L2

5a MIDDLE L2

6 LOW LAU1

6b LOW LAU1

7 LOW LAU1

8a MIDDLE AU2

9 HIGH AU3

9a LOW LAU1

10 HIGH AU3

11 HIGH AU3

13 HIGH L3

14 HIGH AU3

15 LOW LAU1

Results for

Polyurea

Crack bridging

Coating system

bridging

principle

static

bending

> 0,2 mm

bridging

device

3-point bending test with electronic elongation gauge

Test specimen

with failure

Results for Polyurea

Outstanding performances

in all cases > 2mm

Coating over joints = monolithic protection

outdoor exposure

(6 and 24 months)

indoor exposure

(6 and 24 months)

indoor exposure

vertically in wet

surroundings

(storage in boxes

with wet sand)

no degradation

no cracks

no signal for ageing

wear resistance

Test device acc. to EN 13892-4

Methods of test for screed materials

Part 4: determination of wear resistance

Trafficability with BCA tester following

EN 13892-4

for movers - forklifters

procedure adapted for technical approvals

1 cycle: 2850 revolutions

for vulcolan tyres: 2 cycles

for polyamid tyres: 10 cycles

no trace of wear

Electrostatical discharge

(in case of inflammable liquids)

a) with electrostatic discharging top sealer

b) with additives

Formulation with additives and top sealer

without any electrostatical discharging

problems

occurring problems

Blistering by

renunciation

of primer

occurring problems

Adhesion loss

without primer

Executed jobs

Spray application

on geotextile

Spray application

on concrete

retainment basin

system

description

Test of electrical surface resistance

Conclusion

Polyurea based coating systems are able to fulfill

all criterias for ground water protection in industrial

secondary containment according to German

approval guidelines

Lower chemical resistances in comparison with e.g.

the typical range of epoxies compete with a much

higher range of crack bridging capabilities, even with

their performance to bridge joints

Conclusion

Depending of the location (verticals, steric hindrance)

polyurea profit of their ease of application, e.g.

lower number of working steps,

higher range of thickness applicability per step

These added values can be worth higher system

Thanks

attention

patience

Let‘s have

a break !

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