PROTECTIVE COATINGS & LININGSFor

WASTEWATER & WATER

2009

ByRocky Capehart

Accelerated corrosion problems in today’sinfrastructure and a greater awareness ofcorrosion issues, require demanding and

viable long-term solutions.

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 COATINGS & LININGSRESOURCE 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

ASTM Independent Testing PermeabilityTensile/Flexural/Compressive PropertiesChemical Resistance

Material Safety Data Sheets Safety & Handling

Others: NACE, SSPC, and Universities Across North America

Can Help Prevent:

• Polymer Coating and Liner Disbonding• Aggressive Corrosion• Pinholes• Thinner Than Specified Coating Applications• Roots and Infiltration

CORRECT PRODUCT SELECTION,INSTALLATION & INSPECTION

Roots and Infiltration

WRINKLES & SAGS

HOW DO WE SELECT THE CORRECT COATINGOR LINING SYSTEM ?

Thermoplastic sheet liners Cementitious systems

Polymer Systems

STRUCTURAL & NON-STRUCTURALRENEWAL OPTIONS

• Cementitious Coatings (Portlandto Calcium Aluminates')– Structural-1/2”- 4”– Non-Structural-3/8”-1/2”

• Polymer Coatings (Epoxies andPolyurethanes)– Structural-125-500 mils (1/8” –

1/2”)– Non-Structural-60 mils

minimum-100 mils average• Composite Systems

CORROSION PROTECTIONOPTIONS

• Cementitious formulations– Calcium aluminate– Antimicrobial additives

• Thermoplastic linings– Cement or polymer

mastic basecoat• Polymer coatings

– Epoxies,polyurethanes,

polyureas

COATING THICKNESS• New surface (Corrosion Resistance or Chemical Protection)• Profile Height• Effects of hydrostatic head pressure or water vapor transmission

(Design with ASTM 1216-07 for Structural Applications)• 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!

• Understandpreparationprocedures

• Understand repairprocedures:– infiltration or

substrate loss• Know how to test

preparationresults

• Know commonmethods of:– cleaning power– abrasive

choices– coating

removal

COATINGINSPECTION PARAMETERS

• Substrate inspection• Ambient conditions• Surface profile• Surface cleanliness• Mixing procedures• Application

procedures

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: ____________________________________________________________________________________________

InspectionPerformance Acceptable Results

No. Quality Assurance Standard Quality Quality Control Pass/Fail Comments

1

Visual inspection of structuresubstrate after cleaning and

preparationIndustryStandard 100%

Visually inspect surfaces to be coated foreffective removal of existing coatings, unsoundsubstrate, laitance, infiltration. Visually identify

prob lem areas.

2 Test substrate for soundness.

SSPC- SP13 NACE

No. 6 100%

Lightly scratch prepared concrete surfaces with ascrewdriver or pocket knife. The scratch shouldleave a shiny mark with no loose particles fromthe surface. Otherwise, re-prep and re-inspect.

3

Visual inspection of productapplication and documentation of

proper material ratio/usage

ProductTechnical Data

Sheet (ratio) 100%

Visually observe mixed color which should behomogenous without marb ling effect. Inspectionrecordkeeping of applicator for material usage of

product components, verify proper usage.

4

Wet Film Thick ness (WFT)measured during application. NOTE:

When applying fast settingpolyurethanes, this test is not

applicable. Use the adhesion test toalso measure mil thickness. ASTM D-4414

No lessthan 90% orgreater than

120%

Measure and record the WFT in at least fourlocations for every 500 sf and each coat of

material applied.

5Holiday Detection using a high

voltage holiday detector.NACE RPO-

188 100%

Confirm conductivi ty by inducing holiday andcalibrating detector. Test entire coated surface.

Repair and retest as required.

6

Adhesion Testing using a ElcometerModel 106 on a minimum of 10% of

the manhole structures coated. ASTM D-4541As

specified

Perform a minimum of three pull tests permanhole at locations randomly selected.

Evaluate results and repair coating where tested.

Record dolly location, pullstrength (psi), mode of failureand whether dolly was scoredor unscored.

Owners Representative: Name Signature Date

Contractor/Installer Representative: Name Signature DateAll QA/QC as per specific manufacturer's recommendations.

IMPROVED QUALITY CONTROLQA/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 (Steel Structures Painting Council)

– Experience• Similar scope, size or training• Time period

• Established manufacturersthat implement QC duringmanufacturing (ISO 9000)

• Suitable for application inspecified environment

• Capable of providingprotection and/or structuralneeds

• Field tested and proven

Quality Control - Materials

EQUIPMENT• Equipment is product

dependent• Some can be

mobilized intoundergroundstructures asnecessary

• Efficiency andproduction varies

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

ADHESIONA verifiably acceptable mechanical bond to the host structure is essential for

long-term performance.

NOTE: USE MODIFIED ASTM D4541 AND EXPERIENCED INSPECTORS

A CLEAN AND DRY SURFACEWILL 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

Rocky Capehart(916) 686-8055

www.sprayroq.comE-mail: rcapehart@sprayroq.com

QUESTIONS?QUESTIONS?

The Gold StandardThe Gold Standard

Spray AppliedSpray AppliedPolyurethanePolyurethane

ForForWater and WastewaterWater and Wastewater

InfrastructureInfrastructureRehabilitationRehabilitation