Waste Water Coatings and Repair
Protect and repair your facility from hydrogen sulfide damage.
“Eco-Polymer is the one system that Provides Reliable Repair and Anti-corrosive Protection for Water-Wastewater Treatment Plants and in both wet or dry environments”
The Roger Road Wastewater Treatment Plant had an expensive problem; a severely deteriorated concrete splitter box needed to be repaired, but before any work on this operating structure could begin, a temporary but costly "pump around facility" had to be installed to handle the process performed by the splitter box, says John Munden, Civil engineering Manager with the Pima County Wastewater Management Department.
Contact us and receive your Novolac Free Epoxy Guide in 20 seconds!
Pre-job inspection: Severe Hydrogen Sulfide damage
Notice the severe damage from the Hydrogen Sulfide
The splitter box is used to split the flow of raw sewage and direct it to various primary clarifier, he says. The structure was to have been part of a larger project to rehabilitate other concrete structure with a calcium aluminate cement under layment and epoxy topcoat, but the contractor handing that job declined to take on the splitter box, declaring that it couldn't be fixed, say Allen Kauffman, the president of another contracting firm that subsequently did the work using a polymer concrete repair product and an epoxy novolac lining.
North chamber of splitter box: rebar had to be added to the area where 1 foot of cement and rebar was lost due to hydrogen sulfide/sulfuric acid
The covered splitter box is 8 ft wide, and 18ft long, and divided into two sections of different heights to aid in sewage separation. The turbulent contents of the splitter box encourage the development of hydrogen sulfide gas and the subsequent growth of microorganisms that attack the concrete substrate, says Kauffman. In addition, says Munden, the cover exacerbates the hydrogen sulfide problem by trapping the gas, increasing its concentration in the structure.
The deterioration of the splitter box was extensive, but not uniform, says Munden. In some areas affected by sulfuric acid attack, the concrete had lost over 50% of its original thickness. Concrete had been eaten away, exposing rebar. One wall, originally 12 in. (30.5 cm) thick, was reduced to a three-inch (7.6-centimeter) thickness, says Kauffman. The rebar in some areas had been completely corroded, he adds.
Given twelve days to do the work in November 2003, Kauffman’s company began the project by power washing the splitter box at 3,500 PSI (233 bar) to clean the concrete surface and remove loose material. The deteriorated areas were then abrasive blasted with copper slag. The contractor installed a new mat rebar system, securing it to concrete with drilled-in dowels or tying it to the existing rebar. The contractor then performed another power wash with an
Applying polymer concrete repair material to primed wall in order to rebuild wall back to specifications
Wall repaired to Original Specifications
Chamber after final lining application
injection of a soluble salt treatment. Blowers were set up, a five centimeter thick layer, says speed drying, and six hours later, the contractor began apply-Kauffman. The concrete repair material was allowed to setting the polymer concrete repair product by trowel. up for two hours before additional layers were applied.
Working on one wall section at a time, the contractor The contractor built the walls of the concrete structure applied the polymer concrete repair product. Back to their original thickness, in some cases taking a 1/8-inch-thick (3 mm) area back to 10 in. (25 cm). The contractor performed adhesion tests on the concrete repair product, noting that the cementation substrate failed before the polymer concrete repair product. The surface preparation, rebar installation, and rebuilding of the concrete took four days, says Kauffman.
Forced heat aided the cure of the concrete repair material, allowing the contractor to proceed with the lining application 12 hours later. Over two days, two coats of the chemical-resistant epoxy novolac lining were applied by brush and roller to a total thickness between 30 and 35 mils (750 and 875 micrometers). The epoxy novolac was heat cured over the first night and then heat cured for 24 hours following the final application , says Kauffman. According to Kauffman, Pima County had an inspector on site during all working hours.
The concrete splitter box rehabilitation was completed in less than 7 days, saving more money in “pump around facility” expenses than it cost to perform the work, says Kauffman. The contractor performed a follow - up inspection in March 2005, noting no signs of deterioration of the system. Munden says that, although a formal follow-up inspection has not been conducted on the operating splitter box, the lining system appears to be holding up well. He adds that the many of the metal components of the splitter box have been replaced and that it is slated for the installation of a ventilation system for odor control and hydrogen sulfide mitigation.
- SC 1100 Primer a 100% solids, low viscosity hybrid novolac epoxy deep penetrating primer. SC 1100 strikes deep, sealing porous concrete and provides excellent surface for coating to bond to and helps eliminate bubbles caused by out gassing. Mixes easy with sand to form a exceptionally strong and versatile repair mortar for concrete repairs.
- Eco-Crete Lite is a Kevlar-reinforced 100% solids, industrial polymer repair compound for concrete subject to high level of hydrogen sulfide and sulfuric acid. Especially suited for high build repairs and rebuilding on vertical and overhead surfaces Tolerates less than optimal surface conditions especially dampness. Available in fast cure formulation.
- SP 2000 R is a 100% solids hybrid Novolac offering good chemical resistance and excellent adhesion (in excess of 3000 PSI). Also provides good impact resistance and bridges micro fractures in concrete. Effective against salts, alkalis, sewage and dilute mineral acids. Ideal for concrete in aqueous service in water/waste management, wet wells and manholes.
Novolac Epoxy Advantage:
Novolac technology is the cutting edge in epoxies.
- Environmentally safe
(100% solids hybrid NOVOLAC systems, contains no solvents, no volatile or organic compounds) - Superior Bonding
( Bonds both mechanically and chemically to concrete and metal in excess of 3000psi ASTM D 4541) - Higher Chemical Resistance
(Due to its chemistry, this Novolac epoxy has very high chemical resistance's, withstands up to 98% sulfuric acid ) - Higher Temperature
(High Temperature engineered versions are available for service temperatures exceeding 400 °F) - Superior Abrasion Resistant
(ASTM D4060-9 testing for abrasion resistance that the incorporation of alumina oxide ceramic into the matrix provides excellent resistance to abrasion and improves chemical resistance) - Reinforcing Kevlar™ Fibers
(The Addition of reinforcing Kevlar fibers, which are six times stronger than steel, to the epoxy matrix, tremendously increases the flexural and tensile strength by up to 5 to 6 time. This substantially increases wear resistance and greatly reduces the possibility for damage from impact to crack or chip the epoxy.)
We specialize in problem solving facility and utility issues.
All of our Products are:
- User Friendly
- Environmentally safe
- solvent-free
- kevlar reinforced
- nuclear irradiation decontamination
with DBA testing approved for
level 1 nuclear applications - provide excellent resistance for
hydrocarbon oils and fuels
mineral acids and alkalis - tested and used world wide!
