Protective Coatings & Linings 2011 With Notes

8/3/2019 Protective Coatings & Linings 2011 With Notes

1/47

PROTECTIVE COATINGS & LININGSFor

WASTEWATER & WATER STRUCTURES

By

Rocky Capehart

2011


2/47

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!


3/47

Corrosion will increase due to: Reduction of inflow and infiltration

Regulatory changes in pre-treatment

Expansion of collection systems

EPA/625/6-91/030


4/47

How Do We Achieve Long TermQuality Coatings & Linings

Performance?


5/47

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


6/47

Can Help Prevent:

CORRECT PRODUCT SELECTION,

INSTALLATION & INSPECTION


7/47

Polymer Coating and Liner Disbonding


8/47


9/47

Aggressive Corrosion


10/47

Pinholes


11/47

Epoxy FailureThin coating and pinholes


12/47

Inner Coating Delamination & Poor Adhesion


13/47

Thinner Than Required Coating Applications


14/47

Thinner Than Required Coating Applications &Applicator Error


15/47

Roots and Infiltration


16/47

Substrate Failure Behind The Lining


17/47

Equipment / Tool Damage & Pinholes


18/47

WRINKLES & SAGS


19/47

HOW DO WE SELECT THE CORRECT COATINGOR LINING SYSTEM ?

Thermoplastic sheet liners Cementitious systems

Polymer Systems


20/47

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


21/47

CORROSION PROTECTIONOPTIONS

Cementitious formulations Calcium aluminate

Antimicrobial additives

Thermoplastic linings

Cement or polymer

mastic basecoat Polymer coatings

Epoxies,polyurethanes,

polyureas


22/47

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


23/47

UNDERGROUND INSTALLATIONVARIABLES

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

condition Accessibility and confined

space


24/47

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


25/47

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


26/47

IMPROVED QUALITY CONTROL

QA/QC during construction with

Trained Inspectors & Documentation


27/47

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


28/47

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


29/47

EQUIPMENT

Equipment is product

dependent

Some can bemobilized intounderground

structures asnecessary

Efficiency andproduction varies(Brush, roller, troweled

or spray applications)


30/47

VISUAL INSPECTION

Cracking, pinholes, exposedsubstrate

Proper bench and invertrebuild

Frame/chimney sealing

Pipe joint seals

Step removal or replacement


31/47

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


32/47

HOLIDAY (SPARK) TESTINGEQUIPMENT


33/47

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 !


34/47

ADHESION (PULL) TESTINGEQUIPMENT


35/47

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


36/47

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]


37/47

Sprayroq Inc. 37

What is Spraywall?

NOT AN EPOXY!NOT AN EPOXY!


38/47

What is Spraywall?

Spray applied polyurethane

Rigid

Quick Curing

10 second gel time

Reinstate flow in 30-60 minutes

Monolithic finish

Sprayroq Inc. 38


39/47

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


40/47

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


41/47

Sprayroq Inc. 41

Other WastewaterRehabilitation Applications

Wet Wells

Lift Stations

Vaults

Grit chambers

Pipelines (Man entry)

Tunnels

Sedimentation tanks

Secondary Containment


42/47

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


43/47

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


44/47

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


45/47

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


46/47

Sprayroq Inc. 46

SprayWallSprayWallSprayroq Tough!


47/47

The Gold StandardThe Gold Standard

SprayWallSprayWallSpray AppliedSpray Applied

RigidRigid PolyurethanePolyurethane

ForFor

Water and WastewaterWater and WastewaterInfrastructureInfrastructure

RehabilitationRehabilitation

Date post:	06-Apr-2018
Category:	Documents
Upload:	tosaf
View:	226 times
Download:	0 times

Protective Coatings & Linings 2011 With Notes

Documents