Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to...

37
Selecting and Sourcing Coatings for Wastewater Treatment Plants A JPCL eBook

Transcript of Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to...

Page 1: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

Selecting and Sourcing Coatings for WastewaterTreatment Plants

A JPCL eBook

Page 2: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

Selecting and Sourcing Coatings for Wastewater Treatment PlantsA JPCL eBook

Copyright 2011 byTechnology Publishing Company2100 Wharton Street, Suite 310

Pittsburgh, PA 15203

All Rights Reserved

This eBook may not be copied or redistributed without the written permission of the publisher.

i

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Introduction iii

Linings in Wastewater Plants: 1

Real World Performance Evaluation

by Randy Nixon

Coating Systems Guide for Wastewater Plants 10

Coatings Company Profiles 25

Contents

iiContents

1

10

25SPONSORED BY

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iii

Introduction

Introduction

This eBook consists of a recent JPCL article on selecting and using

coatings for protecting municipal wastewater treatment plants, followed

by JPCL Buying Guide material on coating systems for wastewater plant

environments.

The Buying Guide is organized, first, by exposure type, such as

“Exterior Weathering, UV, and Mild Chemical,” then by substrate type,

first steel, then concrete. Then, coating manufacturers are listed in

alphabetical order and their preferred system is named in both

proprietary and generic terms. Finally, contact details are given for all

the companies.

This collection is designed to provide general guidance on selecting

and specifying coatings for wastewater treatment plants, and then to

give sources for acquiring the appropriate systems.

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Linings in Wastewater Plants: Real World Performance Evaluation

LiningWastewater

Plants1

By Randy Nixon,

Corrosion Probe, Inc.

Editor’s note: This article appearedin JPCL in October 2008, and isbased on a paper the author pre-sented at PACE 2008, the jointconference of SSPC and PDCA.

ver the last 19 years, the author has been carefully evaluating the performance of vari-ous protective lining materials in highly corrosive wastewater environments. This ar-ticle presents real world performance evaluation data on seven commonly usedprotective lining systems in wastewater environments and focuses on film quality,chemical resistance, film thickness loss, adhesion, and permeation resistance.

Background

In 1995, widespread and premature coating system failures were identified and studied in influentwet wells, grit classification and removal structures, primary clarifiers, and other channels andtanks at the Deer Island Wastewater Treatment Plant in Boston Harbor. The amine-cured and ami-doamine-cured epoxy coatings and amine-cured coal tar epoxy coatings applied in the headspacesof these various structures had blistered badly, especially at the interface of the vapor phase andthe water line (or scum line) after less than six months of service exposure. The failure was firstreported in the late fall of 1995 and was evaluated by the author in early 1996. While some of thefailures were related to surface preparation inadequacies and initial film quality problems, the ma-jority of the failures involved permeation of the coating films and blister formation, which latercaused cracking and disbondment of the coating films. Over the course of several other investigations of premature coating failures in wastewater

treatment plants between 1993 and 1997, similar failure modes were identified in California,Florida, Louisiana, and New Jersey. As these investigations proceeded, one common thread wasunexpectedly high concentrations of hydrogen sulfide gas. Similarly, coating systems that had longprovided good corrosion protection in wastewater headspaces were routinely failing after only ayear or two of service exposure.

The well-documented corrosion mechanism in theheadspaces of wastewater collection systems andtreatment plants is biogenic sulfide corrosion. It oc-curs when condensation dissolves H2S gas on head-space surfaces, where naturally occurring sulfuroxidizing bacteria metabolize the H2S to form sulfuricacid. Sulfuric acid aggressively reacts with the highlyalkaline concrete, causing degradation of the hydratedcement paste. Sulfuric acid also actively depassivatescarbon steel and ductile iron surfaces found in waste-water systems, causing active corrosion.Much has been written about worsening biogenic sul-fide corrosion rates over the past 10 years. Increasedrates are related to longer detention times in storagetunnels, higher sewerage strength, greater sulfide pro-duction due to legally mandated pretreatment for theremoval of heavy metals, longer transport times dueto urban sprawl, the use of more force mains whereEffluent channel. All photos courtesy of the author.

The author reports on

the performance of

seven types of linings

in severe exposures

at wastewater

collection systems

and treatment plants.

O

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aqueous sulfide production is higher because of theformation of slime layers on full pipe circumfer-ences, and the covering of wastewater tanks andstructures for foul odor containment and control.1

Alternative corrosion protection materials havebeen developed over the past 10 to 15 years to com-bat these higher rates of biogenic sulfide corrosion.The following are the most widely used of the alter-native lining systems in North America.• Anchored polyvinyl chloride (PVC) sheet linings(anchored into concrete when the concrete is placed,followed by heat gun-welding seams)• Fully bonded PVC sheet linings (chemicallybonded to a liquid-applied polyurethane coating mate-rial that is, in turn, adhered to the concrete substrate)• 100% volume solids, blended amine-cured epoxymortars filled with silica or quartz that are applied by

trowel (generally self-priming, 1⁄8-inch- to 1⁄4-inch-thick [3- to 6-millimeter] mortars applied directlyto concrete)• Spray-applied, 100% volume solids, blended amine-cured epoxy linings filled with fibers andsome silica or quartz fine aggregate (generally applied up to 100 to 125 mils [2.5 to 3 mm] dry filmthickness [DFT] using high pressure airless spray equipment)• Spray-applied, unfilled, 100% volume solids, blended amine or novolac epoxy linings (generallyapplied between 30 and 50 mils [0.75 and 1.25 mm] DFT)• Plural-component, heated, spray-applied, 100% volume solids epoxy linings (generally appliedbetween 80 and 200 mils [2 and 5 mm] DFT)• Spray-applied, flexible, oil-modified polyol polyurethane linings (generally spray-applied between50 and 200 mils [1.25 and 5 mm] DFT using metered plural-component airless spray equipment)The objective of this article is to assess actual field performance of the most prevalently used lin-

ing materials in severe wastewater headspace environments. Each of the commonly used types oflining systems was evaluated after a number of years of service in wastewater collection systemsor treatment plants. The exposure conditions have been characterized, and real world perform-ance has been assessed using the evaluation criteria found in Table 1.

Anchored PVC Sheet Linings

Anchored PVC sheet linings have T-shaped or knob-shaped anchors made from PVC on the backof the PVC sheets. The linings are installed as form liners when the concrete is placed. The anchorscan be integrated with the sheet via extrusion, or they can be heat welded to the PVC sheets whenmanufactured. Anchored PVC sheet linings have been used successfully in wastewater service forover 50 years.

In service for 16 years, anchored PVC sheet linings protected the wet well head-space in an influent pump station. This area is exposed to H2S gas concentrationsthat average 125 ppm annually, with excursions over 200 ppm. The surface pHmeasured less than 1.0.

Evaluation• Film Quality: Visual and 30x microscopic examination showed no obvious changesin the PVC sheet, except for discoloration from white to yellowish-brown on the ex-posed surface only (Fig. 1). • Chemical Resistance: Physical examination showed no evidence of embrittlement,softening, or degradation of the PVC.

Parameter

Film or Barrier Quality (Has film quality changed?)

Chemical Resistance (Has lining material been degraded?)

Film Thickness Loss (Has film lost thickness?)

Adhesion (Has film or sheet remained adhered to substrate?)

Permeation Resistance (For purposes of thispaper, we assumed color change from exposed side indicates permeation depth.)

Evaluation Method

Visual and microscopic examination to look forblisters, cracks, discoloration, etc. This includes checking integrity of welded joints for sheet linings.

Physical examination to check for embrittlement,color change, film degradation, etc.

DFT measurement using microscopic (scaled) examination

Adhesion testing in accordance with ASTM D6677and/or physical probing and examination

Microscopic examination of cross sections of lining materials to look for discoloration or othersigns of change through section thickness

Table 1: Evaluation of Lining Properties

Fig. 1: Discoloration only on exposed surface of anchored PVC sheet

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• Film Thickness: Measurements showed no loss of the original PVC wall thickness.The lining remained at its original 65-mil (1.6-millimeter) thickness.• Adhesion: The adhesion of the sheet lining to the concrete remained good. How-ever, one welded joint had opened up, allowing concrete attack to occur behind theliner in a small area. It should be noted that adhesion testing procedures used forcoatings are not appropriate for anchored PVC sheet linings.• Permeation Resistance: Microscopic examination of the cross-section of a smallpiece of lining near the failed seam showed discoloration of the PVC to a depth ofonly 3 to 4 mils (75 to 100 microns). No other signs of degradation could be dis-cerned (Fig. 2). Anchored PVC sheet linings provide excellent performance in environments with

aggressive biogenic sulfide corrosion, which has been well documented for over 40years. A concern, however, is the welding of the PVC, which incorporates a weldstrip that is placed over butt joints and is fused using hot air welding (500 to 600 F;260 to 316 C). Pinholes can develop in this process if the fusing does not proceed in acontinuous motion. Also, the presence of moisture or equipment problems duringfusing can cause poor temperature control, which can result in inadequate fusing.Poor fusing can cause subsequent corrosion, which can continue unnoticed beneaththe sheet lining for a long period of time.

Fully Bonded PVC Sheet Linings

The fully bonded PVC sheet lining system includes an epoxy primer applied directlyover the concrete, followed by a notch trowel-applied polyurethane coating (with asealant-like consistency) applied at approximately 90 to 120 mils (2.2 to 3 mm). Aflexible extruded polyvinyl chloride sheet that is 30 mils (0.75 mm) thick is treatedwith a proprietary chemical activator and is applied over the wet polyurethane coat-ing by pushing and rolling the sheet into the wet urethane. The seams are overlapped4 in. (10 cm), and a polyurethane seam sealer material is applied over the PVC sheetseams.Fully bonded PVC sheet linings protect the headspace surfaces of the primary clar-

ifier. Average H2S gas concentrations in this area range from 30 to 60 ppm, withknown excursions to 350 ppm. Surface pH is normally 2 to 3, with known excur-sions to less than 1.0. The sheet linings have been in service for 9 years.

Evaluation• Film Quality Maintenance: Visual and 30x microscopic examination showed noblisters but did reveal some localized cracking of the PVC sheet, as well as discol-oration.• Chemical Resistance: Physical examination indicated embrittlement and discol-oration of the PVC and a loss of flexibility when compared to a new piece of thesame type of PVC material (Fig. 3). The color went from white to brownish-yellow,and the PVC appeared to be degraded. The polyurethane seam sealer used over thelap joints of the PVC sheets was badly cracked and delaminating. This material ap-pears to be very brittle when compared to the more flexible PVC.• Film Thickness: The film thickness of the PVC remained at 30 mils (0.75 mm).• Adhesion: Physical examination showed the PVC sheet to be fairly well adhered tothe polyurethane mastic below it. The system seemed to be fairly well adhered to theconcrete where it had not cracked (Fig. 4). • Permeation Resistance: Cross-sectional microscopic examination of samples of thePVC sheet removed from service showed the PVC to be discolored throughout its30-mil (0.75-millimeter) thickness. Physical examination showed the PVC material tobe embrittled when compared to a new sample of the same type of PVC sheet.

Fig. 3: Embrittled fully bonded PVC sheet from in-service lining

Fig. 4: Overall good adhesion of fully bonded PVC sheet lining

Fig. 2: Failed seam weld was the only sign of degradation frompermeation on anchored PVC sheet.

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The fully bonded PVC sheet linings seem to provide good performance in preventing biogenicsulfide corrosion of concrete in aggressive headspace environments for up to 9 or 10 years. How-ever, there is cause for concern regarding the embrittlement and/or degradation of the PVC sheet.The performance of the polyurethane seam sealer over the PVC sheets was not good and resultedin acid attack of the substrate at some seam locations. Further research should be conducted tounderstand the embrittlement mechanism for the type of PVC sheets used in this lining system.

Highly Filled, Blended Amine-Cured Epoxy Mortars

Generally cured via a blend of amine curing agents, these 100% volume solids lining systems wereformulated to have good moisture tolerance during cure, including excellent resistance to amineblush. These mortars are highly filled to provide a minimum of 1⁄8 in. (3 mm) of thickness and goodresistance to dilute sulfuric acid and abrasion. Most of these products are based on Bisphenol A orF resins, while some also contain novolac resins. These products provide good workability andprevent pinholing due to their ability to fill air voids. They are generally self-priming and typicallycan be transferred to the lining surfaces using specialized pumps. Application is by trowel, com-monly followed by back rolling.The blended amine-cured epoxy mortar protects the launder trough surfaces of the primary

clarifier. Exposure conditions in this area include high H2S gas concentrations upwards of 150ppm in the hot summer months and surface pH measurements in the range of 1.0 or less. Addi-tionally, the lining is exposed to turbulent flow conditions where wastewater flow changes direc-tion. The epoxy mortar has been in service for 9 years.

Evaluation• Film Quality Maintenance: Visual examination as well as 30x microscopic exami-nation of the in-service lining shows no evidence of blisters, cracking, or disbonding.The lining has discolored from tannish-yellow to dark blotchy brown, with somewhitish indications on it. Cracks in the concrete substrate had propagated throughthe lining at a few locations. At those locations, some minor acidic attack of the con-crete was occurring (Fig. 5).• Chemical Resistance: When probed with a dull putty knife, the lining shows no signof embrittlement or softening. The original roller and trowel marks are present in thefilm. The lining shows no evidence of film degradation in terms of strength loss orsurface hardness.• Film Thickness Loss: A hole saw was used to remove a small disk of the lining. Mi-croscopic examination showed the remaining DFT to be 131 mils (3.3 mm) for a lin-ing that was originally applied at a nominal 125 mils (3.1 mm) DFT.• Adhesion: Adhesion testing in accordance with ASTM D4541 at three locationsgave average results of 320 psi (22 bar) with failure occurring over 90% of the dollysurface area within the concrete. A value of 300 psi (21 bar) is considered very ac-ceptable, especially when the failure plane is within the concrete.• Permeation Resistance: Microscopic examination showed cross-sectional discol-oration emanating from the exposure side of the film to a depth of 25 mils (625 mi-crons). After probing the lining sample at the cross-sectional edge with a sharp knife,no obvious evidence of film degradation was apparent when compared to a new labo-ratory-cured sample of the same lining (Fig. 6). The mortar linings provide excellent protection for concrete in aggressive biogenic

sulfide corrosion environments but are labor intensive to install and do not bridgeactive thermal crack movement. End users should carefully examine the surfaces tobe lined. If active thermal crack movement is expected or prevalent, the specificationshould require special crack treatment measures or the use of more flexible liningmaterials.

Crack propagation with concrete

corrosion

Fig. 6: No obvious sign of film degradation in highly filled,blended epoxy amine-cured mortar

Fig. 5: Minor acidic attack where cracking occured on highly filled, blended epoxy amine-cured mortar

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Filled, 100% Solids Blended Amine-Cured Epoxy Linings

As previously noted, the filled, 100% solids systems have some fillers (fibers or fine aggregate)added to them, but they have a much higher resin-to-filler ratio than the trowelable systems dis-cussed earlier. The resin and curing agent chemistry for these products is very similar to the trow-elable epoxy systems. The filled, 100% solids epoxy amines are applied by spray and provide highfilm build. They are therefore less labor intensive to install when compared to the trowelable sys-tems. However, if the filler/surfacer is improperly applied before the spraying of these products,pinholing related to outgassing from air voids in the concrete can be problematic.The blended amine-cured epoxy linings protect the headspace walls and overhead surfaces ofthe influent channel to the pump station wet well. In these areas, H2S gas concentrations average50 to 60 ppm throughout the year, with excursions up to 85 to 90 ppm in hot summer months.Surface pH measurements gave values of 1.0 to 2.0. The linings have been in service for 5 years.

Evaluation• Film Quality Maintenance: Visual and 30x microscopic examination showed no blisters ormicro-cracking of the lining. Some localized failure in the form of concrete attack was docu-mented, where pinholes had been left in the original lining film when installed. The film had dis-colored from its original tan to brownish-yellow. One actively moving crack in the concrete hadreflected through the lining (Fig. 7).• Chemical Resistance: Physical examination showed no embrittlement or degradation of thefilm. Original sags and roller marks were present, and the film had not softened.• Film Thickness Loss: A hole saw was used to remove the lining material at two locations. Mi-croscopic examination showed an average DFT of 94 mils (2.4 mm). The original specified liningthickness was 100 to 120 mils (2.5 to 3 mm). Visual evidence gave no reason to suspect filmthickness loss had occurred.• Adhesion: Adhesion evaluation using a dull putty knife showed no evidence of disbonding ordelamination. The film could not be removed from the substrate without cutting it and appearedvery well adhered.• Permeation Resistance: Cross-sectional microscopic examination of two removed lining sam-ples (Fig. 8) showed a clear color change in the lining film to a depth of more than 20 mils (500microns).The filled, 100% solids, blended epoxy amines demonstrate good corrosion protection after 5

years of service in a relatively aggressive biogenic sulfide corrosion environment. Further evalu-ation of performance is recommended after 10 years of service exposure. The filled epoxyamines, like the trowelable systems discussed above, are highly susceptible to reflective crackingwhen applied over thermally active cracks in concrete substrates. Additionally, the filled epoxyamines can pinhole if proper filler/surfacer applications do not precede their spray application.

100% Solids, Unfilled, Blended Amine-Cured Epoxy Linings

Unfilled, 100% solids, blended epoxy amine linings are based on very similar chemistry to thefilled and sprayed epoxy linings and trowelable epoxy linings discussed earlier. The designation“unfilled” does not mean that no pigments, drivers, or other solids are used in the formulations;rather, no silica or quartz fillers are added as extenders. Spray-applied, the unfilled epoxy aminelinings have typically been used for new construction. They are applied over polymer-modifiedcementitious or straight cementitious filler/surfacer products. Generally applied between 30and 50 mils (0.75 and 1.25 mm) in one to two coats, they can be applied up to a total of 70 to 80mils (1.75 to 2 mm) DFT. The linings have little to no aggregate or fiber fillers and therefore havevery high resin content. Based on their high resin content, it is expected that the linings developmuch higher curing-related film stresses than the other two types of epoxy linings discussedabove. Because of the higher film stresses, most manufacturers of similar products limit the totalDFT to 40 to 50 mils (1 to 1.25 mm).

Fig. 8: 20-mil discoloration in filled, 100% solidsblended amine-cured epoxy lining

in total of 90+ mils

Fig. 7: Reflective cracking for one actively moving crack in filled, 100% solids, blended

amine-cured epoxy lining

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Unfilled, blended amine-cured epoxy linings protect the headspace surfaces of theinfluent channel to the primary clarifier. H2S gas concentrations in the headspacesurfaces average about 40 ppm annually, with excursions over 100 ppm during thewarmer months of the year. The surface pH has been measured to be between 0 and1.0. The lining has been in service for 4 years.

Evaluation• Film Quality Maintenance: Film quality appeared good after 7 years, with no evi-dence of blisters, cracking, or film degradation. Some localized corrosion craters werepresent where pinholes had formed in the original coating film (Fig. 9). The film wasdiscolored, taking on a brownish blotchy color with whitish streaks.• Chemical Resistance: Physical examination showed no embrittlement or degrada-tion of the film. Original sags, runs, and back roller marks were still present. No soft-ening of the film was detected.• Film Thickness Loss: Chips of the lining were removed at pinhole areas and meas-ured with a micrometer. The remaining film thickness was between 35 and 50 mils(0.9 and 1.25 mm) DFT. The original specified lining thickness was 30 to 40 mils(0.75 to 1 mm) DFT.• Adhesion:Adhesion evaluation using a dull putty knife showed no evidence of dis-bonding or delamination, except at the previously mentioned pinhole or holiday loca-tions. Otherwise, the film could not be removed from the substrate without cuttingit. Adhesion was considered to be good.• Permeation Resistance: Cross-sectional microscopic examination of two samples ofthe removed lining material (Fig. 10) showed a darkening in the lining film to a depthof 10 to 15 mils (250 to 375 microns). The lining products demonstrated good corrosion protection after 7 years in serv-

ice in a relatively aggressive biogenic sulfide corrosion environment. Further per-formance evaluation should be conducted after 10 to 15 years in service. The liningtypes are susceptible to pinholing during application if proper filler/surfacer workdoes not precede their installation. And, like the other two epoxy linings discussedabove, the unfilled linings do not resist reflective crack propagation because theirfilms are quite brittle once cured.

Heated, Spray-Applied 100% Solids Epoxy Linings

Generally based on cycloaliphatic amine or blended amine-cured Bisphenol A or F epoxy resins,heated, spray-applied 100% solids epoxy linings are formulated to have excellent moisture resist-ance during cure. The products are applied using plural-component spray equipment, where the Aand B components are heated between approximately 140 and 150 F (60 and 66 C). Heating re-sults in very rapid initial set times and high film-build capabilities in one coat. The linings are eithervery lightly filled or unfilled and are, therefore, quite high in resin-to-filler ratio. Subsequently, it isexpected that the heated and spray-applied epoxy linings develop very high curing-related filmstresses when compared to the troweled linings or fiber-filled linings discussed above. Like theother unfilled epoxy linings, greater film stresses are expected, due to the high resin content. Theseproducts are applied between 80 and 200 mils (2 and 5 mm) DFT. Therefore, due to such thick-nesses and rapid set times (owing to heating), development of even greater film stress than that ofthe unfilled linings can be expected. It is also likely that such rapid set times and heat cure acceler-ation factors reduce the recoat times for such products.The 100% solids epoxy lining protects wet well headspace surfaces in the pump station. Here,

H2S gas concentrations average about 55 ppm annually, with periodic excursions over 100 ppmduring warmer months of the year. The surface pH has been measured to be between 1.0 and 2.0.The lining has been in service for 6 months.

Fig. 10: Pinhole and cracking locations inheated, spray-applied 100% solids epoxy lining

Fig. 9: Localized corrosion craters at pinholes in 100% solids, unfilled, blended

amine-cured epoxy lining

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Evaluation• Film Quality Maintenance: Film quality appeared very poor after 6 months in service. Numerouspinholes and cracks were present, and the lining was disbonded (Fig. 10).• Chemical Resistance: Physical examination showed no chemical attack of the lining material.Original sags and runs were still present, and no softening of the film was discernible.• Film Thickness Loss: Chips of the disbonded lining were measured for DFT. The thicknessesranged widely between 100 and 200 mils (2.5 and 5 mm). The original specified thickness was 125mils (3.1 mm) DFT.• Adhesion:Adhesion evaluation using a dull putty knife showed evidence of poor adhesion be-tween the epoxy lining and the cementitious surfacer applied before the lining (Fig. 11). The lininghad pulled away from the surfacer and disbonded. The failure zone was within the surfacer or be-tween the lining and the surfacer.• Permeation Resistance: Cross-sectional microscopic examination of the failed lining samplesshowed no discoloration or change in the lining film beneath the exposed surface.These linings provide good chemical resistance to biogenic sulfide corrosion and offer high film-

build properties, excellent moisture tolerance, and rapid initial cure times. However, they are sus-ceptible to developing strong curing-related film stresses, which can result in intercoatdelamination as well as delamination associated with cohesive splitting of weak cementitiousfiller/surfacer materials. In a second installation, this lining type had failed due to intercoat delam-ination between two coats (more than 50 mils [1.25 mm] each) of the lining applied within 24hours of one another. The failure appeared to be associated with exceeding the recoat limitation forthe product.When applied over adequate surface profile and sound filler/surfacers, the linings will likely

perform well in biogenic sulfide corrosion atmospheres. Their formation of strong curing-relatedfilm stresses requires that film thicknesses not be excessive and that associated filler/ surfacersnot be weak. Recoat limitations must be watched carefully for products with especially rapid settimes, particularly epoxies that are heated for application.

Flexible, Oil-Modified Polyol Polyurethane Linings

The flexible, oil-modified polyol polyurethanes are based on the coreactants of isocyanate andvarious polyols. The linings offer reasonable flexibility but are not technically considered to beelastomeric. Because of the isocyanate content, these linings are extremely moisture sensitiveduring application and curing. As such, they must be applied over dry substrates and during dryambient conditions. The linings are typically applied at 50 to 100 mils (1.25 to 2.5 mm) DFT usingplural-component airless spray equipment. The linings offer very rapid set and cure times. Theyare often selected because they offer some recoverable flexibility over cracks that exhibit minimalthermal-related movement.The oil-modified polyol polyurethane lining protects the upper walls and cover of the pump

station’s wet well influent channel. In these areas, H2S gas concentrations averaged between 40and 50 ppm annually, with higher excursions. Surface pH measurements were in the 1.0 range.The lining has been in service for 3 years.

Evaluation• Film Quality: Visual and microscopic examination showed no blisters or cracking in the lining.Some corrosion craters were present where original pinholes had existed in the lining material.The lining remained slighty flexible and did not exhibit any evidence of embrittlement. The lininghad disbonded from the filler/surfacer and the concrete in several areas and was loose wheredetached from those surfaces (Fig. 12).• Chemical Resistance: Physical examination revealed no softening or other signs of film degradationdue to chemical exposure. Some color change had occurred where the lining went from tan to adarker blotchy brown color.

Fig. 11: Splitting of cementious filler/surfacer applied before heated, spray-applied,

100% solids epoxy lining

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• Film Thickness Loss: Samples of the lining were removed and were measured using a micrometer.The thickness varied from 65 to 85 mils (1.6 to 2 mm) DFT. The original lining thickness wasspecified at 40 to 50 mils (1 to 1.2 mm) DFT.• Adhesion:Adhesion was considered poor, given the fact that the lining material had disbondedfrom the substrate and the filler/surfacer material at several locations. When removed, it becameclear that the lining disbonded from the primed surface in the case of both filler/surfacer andthe concrete substrate (Fig. 13).• Permeation Resistance: Cross-sectional microscopic examination of removed samples of thelining showed no discoloration below the upper 1 to 3 mils (25 to 75 microns) of the exposedside.Given proper application under the right, dry conditions, the oil-modified polyol polyurethane

lining type provides good chemical resistance, permeation resistance, and film quality in aggres-sive biogenic sulfide corrosion environments. Based on experience, the linings will bridge minormovement across hairline cracks in concrete substrates. However, the linings are highly moisturesensitive during application and cure, which can result in blister formation, foaming (due to CO2generation from reaction of moisture and isocyanate), and compromised lining adhesion. Also,due to their rapid cure time and associated poor wetting properties and moisture sensitivity, thelinings can develop serious adhesion problems. They must be applied with great care.

Conclusions

Real world experience has shown that there are currently several viable lining technologiesavailable for new construction and existing retrofit applications in wastewater collection systemsand treatment plants where aggressive biogenic sulfide corrosion conditions exist. Choosing the right alternative requires careful consideration of the substrate condition (such

as the presence of active cracking or the depth of prior corrosive attack), the ambient conditionsunder which lining application can be performed, the presence of high moisture vapor transmis-sion through subgrade concrete structures, and the pros and cons of the available lining tech-nologies. This article provides the reader with actual in-service performance information tosupport informed decisions on material selection.

Reference

1. Randy Nixon, “Future Material Selection Guidelines for Coatings on Concrete for ChangingExposure Conditions in Large Municipal Treatment Systems,” Paper No. 379, Corrosion 97,NACE International, 1997.

Randy Nixon is president and founder of Corrosion Probe, Inc., a consulting engineering firm providingengineering, testing, failure analysis, inspection, and project management services. He began his careerwith Georgia Pacific Corp. in 1976 in water/ wastewater engineering, construction, and utilities manage-ment. Between 1979 and 1983, he served in management of specialty contracting services and coatingsengineering for two other firms. He is widely recognized in the coatings industry for his expertise and ex-tensive experience in piping corrosion, concrete degradation evaluation, and coatings/linings for concretesubstrates. He has authored over 25 technical papers and articles.

8

JPCL

Fig. 12: Flexible, oil-modified polyol polyurethanedisbonded from surfacer material

Fig. 13: Chip from disbonded, flexible, oil-modified polyol polyurethane lining

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Page 14: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

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��/"(�)��,* /�.-���)��SurePoxy HiBildEpoxy 100% Solids (1 or 2 Coats)

Listings are alphabetized by company name.

Exterior Weathering, UV,and Mild ChemicalSteel

SPONSORED BY

Coating System Guidefor Wastewater Plants, Municipal

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Coating Systems

Guide

Page 15: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

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� � .00.1).-� .-20.+� .����2$�Techni-Plus UR-5Urethane/Urethane

�)#.0� .,/!-7���-#�Micorthane 6-23Urethane/Urethane

�!2).-� .!2)-'��712%,1���-#�Zn/AlThermal Spray

�.02(%0-��-$3120)%1��-#�Hydro-Seal 75Epoxy Novolac (1 or 2 Coats)

�%-#%� .00.1).-��%04)#%1��� PetroGardTape Wraps

�.+)"0)$� .!2)-'1���-#�Polibrid 705Urethane Elastomeric (1 Coat)

�.+7#.!2��0.$3#21Polyeuro 5502/7502Polyurea Pure (1, 2, or 3 Coats)

�.+7�/%#�������().*.+PolySpec TuffRezEpoxy/Epoxy 100% Solids

�.0����-#�Por-15Urethane/Urethane

�� � .!2)-'1PPC CoatingsOther

�����0.2%#2)4%����!0)-%� .!2)-'1AmercoatEpoxy (1-2 Coats)/Urethane

�0.2%#2.��0!/� .,/!-7Protecto Liner 1350Urethane/Urethane

�3!-23,��0.3/Precidium 41-P, Precidium LS-1150DEpoxy (1-2 Coats)/Urethane

�!4%-��)-)-'��712%,1Raven Lining SystemsEpoxy 100% Solids (1 or 2 Coats)

�()-.��)-)-'1� .0/.0!2).-SolarMaxUrethane/Urethane

�.$$!��!)-2� .0/.0!2).-RoPonHS-Multi-MstrEpoxy (1-2 Coats)/Acrylic (1-2 Coats)

�.4!+����� .0/�Roval R22 Cold Galvanizing CompoundZinc-Rich, Organic

�312��3++%2���� Rust BulletOther

�312��+%3,� .0/.0!2).-9100/9400 SystemEpoxy (1-2 Coats)/Urethane

�!3%0%)1%-���-#�SauereisenEpoxy 100% Solids (1 or 2 Coats)

�(%05)-��)++)!,1Macropoxy 646/Hi-Solids PolyurethaneEpoxy (1-2 Coats)/Urethane

�/%#)!+27��0.$3#21���-#�������Polyshield HT, HT-100F, CAP 100Polyurea Pure (1, 2, or 3 Coats)

�2)0+)-'��+.7$��0.3/��+#�IntegritankMethyl Methacrylate/Methyl Methacrylate

�%0,!0312��%#(-.+.')%1Termarust TR2000 HR CSA SeriesCalcium Sulphonate

�%1+!��!-. .!2)-'1��2$�TeslanZinc-Rich, Organic

�(%0,).-ThermionThermal Spray

�����%2!+)8)-'��712%,1���2$�TMS MetalizingThermal Spray

�-%,%#� .,/!-7���-#�Hi-Build Epoxoline II/Endura-ShieldEpoxy (1-2 Coats)/Urethane

�./��%#0%2� .!2)-'1Top SecretAlkyd/Alkyd/Silicone Alkyd

�12� %-2307� .!2)-'1���-#�FPUWC1Epoxy (1-2 Coats)/Fluoropolymer

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�%01!�+%6��-#.0/.0!2%$FSS 50 DMPolyurea Pure (1, 2, or 3 Coats)

�)130.-��%#(-.+.')%1��-#�PolyArmor, WarriorPolyurea Pure (1, 2, or 3 Coats)

�.+!2)+%��0%%���-#�Volatile Free, Inc.Polyurea Pure (1, 2, or 3 Coats)

�!11%0� .0/.0!2).-WasserMCU Zinc Rich/MCU/MCU

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�.+4%0)-%� .!2)-'1� .0/.0!2).-BondTiteEpoxy/Epoxy 100% Solids

�� !+)"30� .-1203#2).-��712%,1��-#�UraLock 100Organic Zinc/Epoxy/Urethane

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�-$%*� .0/.0!2).-Encapsall SuperUrethane/Urethane

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�.5%01��-$3120)!+DuromarEpoxy/Epoxy 100% Solids

!0".+)-%� .,/!-7CarboguardEpoxy/Epoxy/Epoxy

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(%,#.��-2%0-!2).-!+��2$�Epo-chem RL 500PFEpoxy/Epoxy/Epoxy

(%,�!12%01���-#�Duraguard 400 SeriesMethyl Methacrylate (2 Coats)/Urethane

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.-#0%2%��.+32).-1��)4��.&��()-.��)-)-'1� .0/�Epoxy 200Epoxy/Epoxy 100% Solids

./.+7,%0��0.2%#2).-��712%,1ChemProof PolymersEpoxy/Epoxy 100% Solids

Wastewater Plants SPONSORED BY

11

Page 16: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

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%&&(��$�*()' �(���$��Armorgard 700UVEpoxy/Epoxy 100% Solids

%'���#�%'&%'�) %$Corchem 260/274Epoxy (1-2 Coats)/Urethane

%'%"%$�%�) $�(���%''%( %$�%$)'%"������Corolon TEpoxy Coal Tar/Epoxy Coal Tar

%'%)����� �����'�%'#�$���%�) $�(CortechEpoxy (1-2 Coats)/Urethane

%''%��� �"���$)�'$�) %$�"���$��Corro Aqua-ShieldEpoxy/Epoxy/Epoxy

'%((� �"���'%�*�)(�%'&�Dex-O-TexEpoxy (1-2 Coats)/Urethane

'%,$��%".#�'(����CrownShield 40 No VOCEpoxy/Epoxy 100% Solids

�$(%��%')���#�' ��DensoTape Wraps

�+%�������$)�'$�) %$�"��� $)����Devoe High Performance CoatingsEpoxy (1-2 Coats)/Urethane

�#%$���%��"��� $)�%#&�$.Vers-Acryl 200/Vers-Acryl 222Other

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�$�*'����$*���)*' $��%���)��HiBuild/EX-2CEpoxy (1-2 Coats)/Urethane

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�%-��$�*()' �(��$��Fox FX-70-9 Hydro Ester CoatingEpoxy 100% Solids (1 or 2 Coats)

���%�) $�(��$��Bio-Safe Prime & Seal/MaxLifeAlkyd/Acrylic/Acrylic

�'%$��'%�*�)(���$��Mortarthane/AccelaresinPolyurea Hybrid (1, 2, or 3 Coats)

�# )���'%�*�)(��$��Cem-Kote STOther

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��$!�"�%'&%'�) %$/%''%( %$��$� $��' $�Penncoat 331Vinyl Ester/Vinyl Ester/Vinyl Ester

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Rhino Linings is a leading manufacturerof spray, brush and roller-appliedcoatings. They can be applied toconcrete, masonry, steel, geotextile and

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The next time you need tough protective coatings,use the #1 brand name chosen by hundreds ofpeople every day. Rhino Linings offers both 1:1and 2:1 mix ratio products.

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Call Rhino Industrial today!

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The photos depicted in this advertisement are shown forillustration purposes only and are not intended to representparticular applications or methods. All businesses areindependently owned and operated. ©2011 Rhino LiningsCorporation. All rights reserved. JPCL0411 6032

The more complex yourcontainment and corrosion problems, the more you need the Rhino™

solution.

The more complex yourcontainment and corrosionproblems, themore you needthe Rhino™

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Wastewater Plants

12

Page 17: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

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Interior Exposure EnvironmentSteel

Wastewater Plants SPONSORED BY

13

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Wastewater Plants

14

Page 19: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

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Page 20: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

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Wastewater Plants

16

Page 21: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

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Wastewater Plants SPONSORED BY

17

Page 22: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

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Page 24: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

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Page 25: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

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Page 34: Selecting and Sourcing Coatings for Wastewater Treatment ... · This collection is designed to provide general guidance on selecting ... oration. • Chemical Resistance: Physical

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