PROTECTIVE COATINGS & LININGS For WASTEWATER & WATER STRUCTURES. By Rocky Capehart

Transcription

1 PROTECTIVE COATINGS & LININGS For WASTEWATER & WATER STRUCTURES 2011 By Rocky Capehart

2 Accelerated corrosion problems in today s infrastructure and a greater awareness of corrosion 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 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 How Do We Achieve Long Term Quality Coatings & Linings Performance?

5 THIRD PARTY TESTING AND SPECIFICATIONS RESOURCE Los Angeles County Sanitation Greenbook - City of Los Angeles Trenchless Technology Center Independent Testing Labs (Following ASTM Standards) Material Safety Data Sheets PROPERTIES Ease of Application Chemical Resistance Bond Inspection Chemical Resistance Change in Physical Properties Buckling Strength Hydrostatic Pressure Effects Permeability Tensile/Flexural/Compressive Properties Chemical Resistance Safety & Handling Others: NACE (National Association of Corrosion Engineers), SSPC (The Society for Protective Coatings), ICRI (International Concrete Repair Institute) and Universities Across North America

6 CORRECT PRODUCT SELECTION, INSTALLATION & INSPECTION Can Help Prevent:

7 Polymer Coating and Liner Disbonding

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9 Aggressive Corrosion

10 Pinholes

11 Epoxy Failure Thin coating and pinholes

12 Inner Coating Delamination & Poor Adhesion

13 Thinner Than Required Coating Applications

14 Thinner Than Required Coating Applications & Applicator Error

15 Roots and Infiltration

16 Substrate Failure Behind The Lining

17 Equipment / Tool Damage & Pinholes

18 WRINKLES & SAGS

19 HOW DO WE SELECT THE CORRECT COATING OR LINING SYSTEM? Polymer Systems Thermoplastic sheet liners Cementitious systems

20 STRUCTURAL & NON-STRUCTURAL RENEWAL OPTIONS Cementitious Coatings (Portland to Calcium Aluminates') Structural-1/2-4 (May require reinforcement) Non-Structural-3/8-1/2 Polymer Coatings (Epoxies and Polyurethanes) Structural mils (1/8 1/2 ) Non-Structural-60 mils minimum-100 mils average Composite Systems

21 CORROSION PROTECTION OPTIONS Cementitious formulations Calcium aluminate Antimicrobial additives Thermoplastic linings Cement or polymer mastic basecoat Polymer coatings Epoxies, polyurethanes, polyureas

22 COATING THICKNESS Profile Height (New surface or Exposed Aggregate) Effects of hydrostatic head pressure or water vapor transmission (Design with industry accepted ASTM F for Structural Applications to withstand long term external hydrostatic loadings) Environment

23 UNDERGROUND INSTALLATION VARIABLES Temperature and humidity Moisture filled substrates Hydrostatic pressure Water vapor transmission Surface and structure condition Accessibility and confined space

24 KEY FACTORS FOR PREP SUCCESS Obtain a clean, dry and sound surface! Understand repair procedures: Substrate loss or infiltration Understand preparation procedures Know how to test preparation results Know common methods of: cleaning power abrasive choices coating removal

25 COATING INSPECTION PARAMETERS Substrate inspection - Ambient conditions - Surface profile - Surface cleanliness Mixing procedures - Application procedures SAM PLE FORM Quality Assurance/Quality Control Contract 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 2 Visual inspection of structure substrate after cleaning and preparation Industry Standard Test substrate for soundness. SSPCSP 13 NACE No % Visually inspect surfaces to be coated for effective removal of existing coatings, unsound substrate, laitance, infiltration. Visually identify prob lem areas. 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. Product Technical Data Sheet (ratio) 100% Visually observe mixed color which should b e homogenous without marbling effect. Inspection recordkeeping of applicator for material usage of product components, verify proper usage. 4 Visual inspection of product application and documentation of proper material ratio/usage Wet Film Thick ness (WFT) measured during application. NOTE: When applying fast setting polyurethanes, this test is not applicable. Use the adhesion test to also measure mil thick ness. 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 % 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. As specified Perform a minimum of three pull tests per manhole at locations randomly selected. Evaluate results and repair coating where tested. 3 ASTM D-4541 Owners Representative: Name Contractor/Installer Representative: Name Al l QA/QC as per speci fi c manufa cturer's recommendati ons. Signature Record dolly location, pull strength (psi), mode of failure and whether dolly was scored or unscored. Date Signature Date

26 IMPROVED QUALITY CONTROL QA/QC during construction with Trained Inspectors & Documentation

27 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

28 Quality Control - Materials Established manufacturers that implement QC during manufacturing (ISO 9000) Suitable for application in specified environment Capable of providing protection and/or structural needs Field tested and proven Independent and certified third party laboratory testing

29 EQUIPMENT Equipment is product dependent Some can be mobilized into underground structures as necessary Efficiency and production varies (Brush, roller, troweled or spray applications)

30 VISUAL INSPECTION Cracking, pinholes, exposed substrate Proper bench and invert rebuild Frame/chimney sealing Pipe joint seals Step removal or replacement

31 MONOLITHIC INSTALLATION Holiday (Spark) Testing A barrier without fault provides effective long-term elimination of infiltration and corrosion protection Refer to NACE RPO188-Concrete & Steel Refer to ASTM G Steel Pipe

32 HOLIDAY (SPARK) TESTING EQUIPMENT

33 ADHESION A verifiably acceptable mechanical bond to the host structure is essential for long-term performance. USE EXPERIENCED INSPECTORS FOLLOW ASTM D or MODIFIED ASTM D STANDARDS NOTE: ASTM D includes cohesion and adhesion test formulas A CLEAN AND DRY SURFACE WILL PROVIDE OPTIMAL RESULTS!

34 ADHESION (PULL) TESTING EQUIPMENT

35 REMEMBER THE SEVEN Ps! 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 The Gold Standard Spray Applied Polyurethane For Water and Wastewater Infrastructure Rehabilitation Rocky Capehart (916)

37 What is Spraywall? NOT AN EPOXY! Sprayroq Inc. 37

38 What is Spraywall? Spray applied polyurethane Rigid Quick Curing 10 second gel time Reinstate flow in minutes Monolithic finish Sprayroq Inc. 38

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 technical properties Passed the Redner Study (L.A. County) Passed the Greenbook Pickle Jar Test Chemical Resistance Tested as per ASTM D543 Sprayroq Inc. 39

40 Spraywall Properties Technical Properties 730,000 psi Flex Modulus (45% stronger than the original concrete structure) 3.8% elongation Tensile 7,450 psi Compressive Strength >18,000 psi Pull test yields at 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. 40

41 Other Wastewater Rehabilitation Applications Wet Wells Lift Stations Vaults Grit chambers Pipelines (Man entry) Tunnels Sedimentation tanks Secondary Containment Sprayroq Inc. 41

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 Sprayroq Inc. 42

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. 43

44 Training Class-In the Field Sprayroq Operations team travels to SCP facilities for one week 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. 44

45 Third Party Testing Conducted currently by Texas Research Institute in Austin, TX Complete test panels Flex Modulus Elongation Tensile strength Compressive strength Louisiana Tech U completed study verifying bursting strength (internal) of Spraywall St. Louis Testing Laboratories Chemical Resistance as per ASTM D543 Sprayroq Inc. 45

46 SprayWall Sprayroq Tough! Sprayroq Inc. 46

47 The Gold Standard SprayWall Spray Applied Rigid Polyurethane For Water and Wastewater Infrastructure Rehabilitation