Rehabilitation Coatings The Secret to Successful Installation CMOM 2013 Capacity, Management, Operation & Maintenance Austin, TX Mike Fleury, P.E., BCEE August 27, 2013

Agenda • • • • • • • •

Wastewater Corrosion Issues Confined Space Entry Contractor/Applicator Experience Surface Preparation Materials Testing Warranty Case Studies

Wastewater Corrosion Issues

Wastewater Corrosion Issues H 2S

Location of H2S oxidizing bacteria H2SO4 H2S + 2O2

O2 H 2S O2

O2

O2

H 2S

Confined Space Entry

Work Together As A Team You Are Not Alone

Confined Space Entry to do List • Daily Safety Talks • Check Safety Equipment • Practice Evacuation Drills • Keep An Eye On New Personal • Identify All Possible Confined Space Exits

Confined Space Entry to do List (cont) • Continuously Monitor Air Quality/Forced Ventilation • Keep Hardwire Communication With Top Side Crew w/Backup • Always Use Secondary Lanyard When Lowering Personal

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Contractor/Applicator Experience

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Contractor/Applicator Experience • Minimum Experience Requirements • Applicator Certified by the Coatings System Manufacturer • Coating System Application Plan • Applicator Quality Assurance Manager

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Infrastructure Rehabilitation #1 Problem Lack of Skilled Labor Classroom and Field Training Is…

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Surface Preparation

Surface Preparation Checklist • Pipe and Structure Cleaning Spec  Cleaning Plan  Cleaning process to remove all contaminants, oil, grease, existing linings/coatings, waxes, form release, curing compounds, efflorescence, sealers, salts, etc.  Schedule  Provide references for cleaning method  Mitigation plan for impact to public  Traffic control  Dewatering or Bypassing Provisions  Field Preparation and Application Logs (Contractor)

Surface Preparation - Cleaning • Use Skilled Labor • Clean entire structure including frame, walls, bench, pipe • Initial Abrasive Blasting and/or Low-Pressure Water  Coordinate Method with Coating Manufacturer/Engineer • Low-Pressure Application of Trisodiumphosphate (TSP) • Acid Etch Surface – 20% Muriatic Acid Solution • High-Pressure Water Blast – 5,000 to 10,000 psi  Use Dilute Solution of Chlorine • Low-Pressure Water Rinse • Test Surface pH – Near 7 and not to exceed 8.5

Field Preparation & Application Log

Materials

Polyurea Liners (3 layer system) • Corrosion resistant • VOC’s requires special precautions in confined space work areas • Toxic, not environmentally friendly • Bonds to dry concrete only for new and rehabilitation applications

Polyurea Liners (cont.) • Silicon modified polyurea primer • Surfacing coat of closed cell polyurethane foam • Barrier coat of silicon modified polyurea • Fast curing in hot temperatures only • Average adhesion (200-250 psi max.)

Recent Safety Awareness Bulletin for the Coating Industry Re: Polyurea (Isocyanates) • OSHA INSTRUCTION-Directive CPL 03-00-017 • June 20, 2013 • National Emphasis Program- Occupational Exposure to Isocyanates • Jobs that involve exposure include painting, blowing foam insulation, etc. • Health effects include occupational asthma, irritation of the skin (dermatitis), and mucous membranes (eyes, nose, and throat), hypersensitivity pneumonitis, and chest tightness. 20

Urethane/Epoxy Liners (2 layer system) • Corrosion resistant • VOC’s requires special precautions in confined space work areas • Toxic, not environmentally friendly • Bonds to dry concrete only for new and rehabilitation applications

Urethane/Epoxy Liners (cont.) • Requires underlayment • Fast curing in hot temperatures only • Not NSF approved for potable water applications • Average adhesion (200-250 psi max.)

Epoxy Liner (single layer system) • 100% solids epoxy resin • Corrosion resistant • Superior structural values for increased strength • Zero VOC’s for superior application and safety in confined space work areas • Non toxic, environmentally friendly • Bonds to moist concrete: can also bond to steel, PVC, and HDPE for new and rehabilitation applications

Epoxy Liners (cont.) • Fast curing in hot and cold temperatures • Average adhesion (900-1000 psi min. w/glue failure)

Testing

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Testing • Spark Testing- 100 volts per mil minimum • Adhesion Testing- ASTM D7234-05 for both the underlayment and coating system, minimum of one for every four manholes and two for each structure, min. 250 psi

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Warranty

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Warranty • Coating manufacturer provides a written bonded warranty(5-10 years) • Warranty covers workmanship and materials • Coating failure defined as blistering, cracking, embrittlement, or softening, or failure to adhere to the substrate • Applies to repair materials and labor

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Case Studies w/Epoxy Liner (1 layer)

Project No. 1 City of Austin Lift Station Force Main Dicharge ManholeRehabilitation Demonstration

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Warren Environmental Epoxy Coating

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Warren Environmental Epoxy Coating

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Project No. 2 City of Las Vegas Brick Manhole Rehabilitation Demonstration

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Warren Environmental Epoxy Coating

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Warren Environmental Epoxy Coating

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Project No. 3 Victor Valley Wastewater Reclamation District Victor Valley Interceptor Manhole Rehabilitation

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Project Location Map

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Limits of Field Investigations/Technologies

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Victor Valley Interceptor • • • • •

Approx. 38,800 LF of VCP and Steel Pipe 27”-36” diameter constructed in 1979 Flow rate of 14 MGD ADWF Serves 110,000 people in the high desert Victorville, Hesperia, Apple Valley, and San Bernardino County service areas of Spring Valley Lake and Oro Grande

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Manhole Rehabilitation Project 52 manholes • Prepared detailed specifications and drawings • Two coating manufacturers listed in specifications •

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Manhole Rehabilitation Epoxy Coating

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Manhole Rehabilitation Preparation

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Manhole Rehabilitation Structural Epoxy Coating

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Manhole Rehabilitation Epoxy Coating

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Spark Testing

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Adhesion Testing GERMANN 2-PART EPOXY GLUE 20 MM DOLLIE

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Adhesion Testing DOLLIE PLACEMENT

DELFELSKO EQUIPMENT

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Adhesion Testing Results Manhole I.D.

Area

Coating Thickness

Failure Mode

SVL-23

Rehab Cone

>150 mils epoxy

800 psi glue failure

SVL-22

New Barrel

>125 mils epoxy

350 psi glue failure

SVL-17

Rehab Cone

>250 mils epoxy

475 psi glue failure

SVL-14

Rehab Barrel

>250 mils epoxy

725 psi glue failure

SVL-9

Rehab Bench

>250 mils epoxy

90 psi substrate failure

SVL-5

Rehab Cone

>250 mils epoxy

1,100 psi glue failure

MH 4-8

Rehab Barrel

>500 mils epoxy

1,150 psi substrate

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Questions? Mike Fleury – [email protected]