PROTECTIVE COATINGS & LININGS

For WASTEWATER & WATER STRUCTURES

2011

By Rocky Capehart

Accelerated corrosion problems in todays 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!

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 Term Quality Coatings & Linings Performance?

THIRD PARTY TESTING AND SPECIFICATIONS

RESOURCE Los Angeles County Sanitation 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

Greenbook - City of Los Angeles

Trenchless Technology Center

Independent Testing Labs (Following ASTM Standards)

Material Safety Data Sheets

Others: NACE (National Association of Corrosion Engineers), SSPC (The Society for Protective Coatings), ICRI (International Concrete Repair Institute) and Universities Across North America

CORRECT PRODUCT SELECTION, INSTALLATION & INSPECTION

Can Help Prevent:

Polymer Coating and Liner Disbonding

Aggressive Corrosion

Pinholes

Epoxy Failure Thin coating and pinholes

Inner Coating Delamination & Poor Adhesion

Thinner Than Required Coating Applications

Thinner Than Required Coating Applications & Applicator Error

Roots and Infiltration

Substrate Failure Behind The Lining

Equipment / Tool Damage & Pinholes

WRINKLES & SAGS

HOW DO WE SELECT THE CORRECT COATING OR LINING SYSTEM ?

Polymer Systems

Thermoplastic sheet liners

Cementitious systems

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-125-500 mils (1/8 1/2) Non-Structural-60 mils minimum-100 mils average Composite Systems

CORROSION PROTECTION OPTIONS

Cementitious formulations Calcium aluminate Antimicrobial additives Thermoplastic linings Cement or polymer mastic 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 Structural Applications to withstand long term external hydrostatic loadings) Environment

UNDERGROUND INSTALLATION VARIABLES

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

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

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 Visual inspection of structure substrate after cleaning and preparation
Visually inspect surfaces to be coated for effective removal of existing coatings, unsound substrate, laitance, infiltration. Visually identify prob lem areas. 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. 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.

Industry Standard SSPCSP 13 NACE No. 6 Product Technical Data Sheet (ratio)

100%

Test substrate for soundness. 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.

100%

100%

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. Confirm conductivity by inducing holiday and calib rating detector. Test entire coated surface. Repair and retest as required. 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.

Holiday Detection using a high voltage holiday detector. Adhesion Testing using a Elcometer Model 106 on a minimum of 10% of the manhole structures coated.

NACE RPO188

100%

ASTM D-4541

As specified

Owners Representative: Name Contractor/Installer Representative: Name

Al l QA/QC as per speci fi c manufa cturer's recommendati ons.

Signature Signature

Date Date

IMPROVED QUALITY CONTROL

QA/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 SSPC
(National Association of Corrosion Engineers) (The Society for Protective Coatings)

Experience
Similar scope, size or training Actual Field Experience References

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

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

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

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 G627-87-Steel Pipe

HOLIDAY (SPARK) TESTING EQUIPMENT

ADHESION
A 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 !

ADHESION (PULL) TESTING EQUIPMENT

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

The Gold Standard

Spray Applied Polyurethane For Water and Wastewater Infrastructure Rehabilitation www.sprayroq.com
Rocky Capehart (916) 686-8055 686E-mail: rcapehart@sprayroq.com

What is Spraywall?

NOT AN EPOXY!

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What is Spraywall?
Spray applied polyurethane Rigid Quick Curing 10 second gel time Reinstate flow in 30-60 minutes Monolithic finish

Sprayroq Inc.

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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
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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

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Other Wastewater Rehabilitation Applications

Wet Wells Lift Stations Vaults Grit chambers Pipelines (Man entry) Tunnels Sedimentation tanks Secondary Containment

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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

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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

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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

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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
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SprayWall
Sprayroq Tough!

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The Gold Standard SprayWall

Spray Applied Rigid Polyurethane For Water and Wastewater Infrastructure Rehabilitation