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New Options for Coating Water and Wastewater Treatment Plants Presented by Bruce Snyder Business Development Manager Water and Wastewater.

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Presentation on theme: "New Options for Coating Water and Wastewater Treatment Plants Presented by Bruce Snyder Business Development Manager Water and Wastewater."— Presentation transcript:

1 New Options for Coating Water and Wastewater Treatment Plants Presented by Bruce Snyder Business Development Manager Water and Wastewater

2 Protective Coatings Technologies Coatings technology for years remained the same. Raw material supplier began to seek a competitive advantage. Coatings manufacturers began to take advantage of new technologies. Today, coatings technologies are improving like electronics (very frequently).

3 Why? Prior to the Clean Water Act of 1972, H 2 S concentrations were below 10 ppm in most municipal systems. The result was very gradual acid attack to concrete and metals. As a result, thin film systems (<25m) such as coal tar epoxy provided effective protection for 10-15 years.

4 1980 Following the amendment of the Clean Water Act of 1980, industrial pretreatment of wastewater affluent to eliminate or reduce the presence of heavy metals (lead, mercury, cadmium) was mandated. Prior to 1980, these metals killed or retarded the growth of bacteria.

5 Add Covers and Longer Detention Times Consequently, H 2 S has risen to levels as high as several hundred ppm, averaging over 30 ppm in collection piping, manholes and tanks. H 2 SO 4 concentrations have risen from solutions of 1.5% to as high as 7%, resulting in pH ranges found to be as low as 1.5-2.5, and often less than 1.0 ! add decreased inflow/infiltration


7 The Result Coating systems that served well prior to 1980, like coal tar epoxy, now often fail in months, not years! Microbial H 2 SO 4 generation attacks steel, concrete, and ductile iron.




11 Controlling Corrosion 1. Change design parameters. (Minimize slow flow or stagnant conditions in treatment stream) 2. Different materials of construction. (Use of vitrified clay, ductile iron, plastics, anti-microbial concrete) 3. Modification of sewage environment. (Raise pH above 9 temporarily to kill SRB; sulfate reducing bacteria) 4. Installation of barrier coatings!

12 Selection Criteria Remember! – ALL ORGANIC MATERIALS ARE PERMEABLE “Select materials or systems that provide optimum balance of performance, risk, and cost factors” (Quote – Concrete Repair Manual Vol. 1)

13 Why Flake Filled Topcoat? Flake Filled with inert material –MIO, Graphite, Glass, Mica Lower Co-Efficient of Expansion Reduce permeability (immersion service) Increase abrasion resistance Reinforces coating tensile & flexural strength

14 Micaceous Iron Oxide Fe 2 O 3 Crystals of MIO are fractured into thin flakes. Flakes then align in parallel fashion.

15 Types Of Flake Reinforcement GlassGlass Micaceous Iron Oxide (MIO)Micaceous Iron Oxide (MIO) GraphiteGraphite (resistance to halogenated acids)

16 Glass Flake Reinforced Amine Epoxy Upgrade to coal tar epoxy Lower permeability Corrosion, impact, and abrasion resistant Higher dry film thickness than unreinforced epoxies

17 Fast Cure Reinforced Immersion Grade Urethane Typically aromatic polyurethanes MIO reinforced Resistant to H2S and MIC corrosion Low temperature application Fast dry and cure times Monolithic application

18 100% Solids Epoxy Lining / Mortar/FRE Amine cured Chemical Resistant Resistant to hydrogen sulfide gas, carbon dioxide gas, and microbiologically induced corrosion, and sulfuric acid attack. High build capabilities

19 100% Solids Epoxy Lining


21 100% Solids Polyurethane Elastomer Aromatic polyurethane High film build capabilities Flexibility Quick setting – short downtime Chemical resistance Excellent abrasion and impact resistant Vertical & overhead application Monolithic application

22 Manhole Rehabilitation

23 100% Solids Polyurethane Elastomer

24 Fast Cure Polyurea Fast set and cure, short downtime Seamless, flexible and waterproof Chemical resistant Impact, tear, and abrasion resistant Bridges moving cracks to 1/8" Retains physical properties at -20°F to 250°F

25 Fast Cure Polyurea

26 AR425 Polyurea

27 Manhole Rehabilitation

28 Why? Stop I/I (Infiltration and Inflow) and Rebuild

29 Chemical Grouts Chemical Grouts are broken down into 4 basic Categories. 1.Acrylamide 2.Acrylate 3.Acrylic 4.Polyurethane

30 Polyurethane’s Polyurethane Chemical Grouts are broken in to three categories. 1.Hydrophobic 2.Hydrophilic 3.Multi Component

31 Hydrophilic & Hydrophobic Hydrophilic Flexible Resin only Great Bond Absorbs Water Medium to High Shrinkage Medium Expansion Foam or Gel Hydrophobic Rigid and Flexible Resin + Catalyst Good Bond Repeals Water Low Shrinkage High Expansion Adjustable Set Times Foam

32 Injection Procedures INJECTION STEPS 1.Determine the location of the leaks. 2.Slow Down Water Flow. 3.Drill Injection Port Holes 4.Insert injection Port or Wall Spear. 5.Mix Material 6.Inject Material

33 Insertion of Ports/Wall Spear

34 Injecting the back side

35 Complete encapsulation

36 Hydrophilic & Hydrophobic Polyurethane Grouts Here are four products designed to solve problems in Manholes: Polyurethane foam A flexible Polyurethane for cracks and pipe penetration. Hydrophobic: A Polyurethane capable of shutting off gushing leaks and filling voids. Gel : A Polyurethane gel that will seal leaks and stop infiltration through the walls. OAKUM: A dry jute rope when soaked in Polyurethane is capable of filling large cracks. Grouting Leaks in main line pipes can easily be accomplished using Acrylates or Acrylamide grouts.

37 Cementitious Repair Coatings Portland cement by-products or calcium aluminates Sprayed or trowel applied New product mixes allow radial spray with no entry into manhole Will degrade as the original surface did

38 Micro Silica/Fumed Silica Mortars Advantages 1.Tighter matrix – lower permeability 2.Chemical resistant 3.Drive water off faster than pure portland Disadvantages 1. Susceptible to MIC 2. Longer overcoat time than Calcium Aluminate Mortar

39 Microsilcate Application



42 Calcium Aluminate Mortar Advantages 1.With stands MIC longer than portland based materials 2.Faster set times (Typically 4-24 hours) 3.Can be used as a stand alone liner Disadvantages 1. Susceptible to MIC, but at a reduced rate. 2. Cost Two types available in the market. Pure Calcium Aluminate Mortar Binder or paste are calcium aluminate as well as the aggregate. Calcium Aluminate Mortar Binder or paste are calcium aluminate and the aggregate is typically silicon dioxide (Silica Sand)

43 Questions?

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