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North chamber of splitter box: rebar had to be added to the area where 1 foot of cement and rebar was lost due to chemical attack by hydrogen sulfide/sulfuric acid

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

injection of a soluble salt treatment. Blowers were set up to mately two-inch (five-centimeter) thick layers, says speed drying, and six hours later, the contractor began apply-Kauffman. The concrete repair material was allowed to set ing 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 thicknesses, in some cases taking a¹/8-inch-thick (3 mm) area back to 10 in. (25 cm). The contractor performed adhesion tests on the concrete repair product, noting that the cementitious 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 fo l l o w - u p inspection in March 2005, noting no signs of deterioration of the system. Munden says that, although a fo r m a l 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 isa 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.

Waste Water Coatings and Repair

“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”

Call Now for more detailed information about your project
@ Toll Free (888) 858-3790.

For a COMPLETE NO COST diagnosis for your project, Product Data Sheets, MSDS sheets, and Step by Step Surface Preparation Iinstructions.

Contact our applications department.

Waste Water Coatings and Repair

“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”

Call Now for more detailed information about your project @ Toll Free (888) 858-3790.

For a COMPLETE NO COST diagnosis for your project, Product Data Sheets, MSDS sheets, and Step by Step Surface Preparation Iinstructions.

Contact our applications department.

Call Now for more detailed information about your project
@ Toll Free (888) 858-3790.