MAINTENANCE & REHABILITATION OF SEWERS, MANHOLES & WASTEWATER TREATMENT FACILITIES

Presented by:
BARRY BARMAN, PRINCIPAL CONSULTANT
Barry Barman & Associates, Inc (805-368-0354)

TOPICS
The Maintenance Survey Alternative Methods of Remediation Liquid Applied Coatings Sheet Applied Products Specifications Contractor Qualifications Inspection

STRUCTURES
Manholes

STRUCTURES
Sewer Lines

STRUCTURES
Wastewater Treatment Facilities
Concrete & Steel
Atmospheric Immersion Splash zone

REHAB OF MANHOLES AND SEWERS

Remove and Replace Cementitious Thermoplastic Liners Cured-in-Place Polymers

MAINTENANCE OF PLANT & EQUIPMENT

Liquid Applied Coatings (thick Film)
Epoxies Polyureas Elastomeric Polyurethanes

Liquid applied Coatings (thin Film)

Epoxy/urethane Epoxy/acrylic Acrylic/acrylic

Vinyl Sheet Products

TYPICAL OPTIONS (Liquid Applied Coatings)

Spot Repair Spot repair and Overcoat Total Removal and Replacement Combination

CONDITION ASSESSMENT
Extent of coating defects Adhesion of coating to itself and the substrate Thickness of existing paint system (thin film systems on steel) Condition of underlying substrate

EXTENT OF COATING DEFECTS

A Good condition; with up to 0.3% corrosion or defects B+ Slight touch-up; 0.3-1% corrosion & defects B Average touch-up; 1-3% corrosion & defects B- Considerable touch-up; 3-10% corrosion & defects C Beyond touch-up; greater than 10% corrosion & defects

Typical A Condition

Typical B+ Condition

Typical B Condition

Typical B- Condition

Typical C Condition

Typical Waited Too Long Condition

THICKNESS OF PAINT SYSTEM

As paint increases in thickness, the internal stress increases There is a finite amount of paint that can be applied (thin film systems) Rule of thumb - total thickness greater than 30 mils is not recommended (for thin film systems)

ADHESION
Adhesion pull testing ASTM D 4541 fixed alignment self-aligning type testers

ADHESION
Adhesion by tape test ASTM D 3359 Method A (X-scribe) Method B (cross hatch) Adhesion by knife probing ASTM D 6677
Subjective probing (scale of 2 to 10)

CONDITION OF THE SUBSTRATE

Is there loose rust or under-film corrosion present Is there mill scale present Is there an anchor profile present from original or subsequent coating operations Is the concrete sound

CONDITION ASSESSMENT OVERVIEW

CAN THE STRUCTURE BE OVERCOATED < 10% coating defects minimum of 200 psi tensile adhesion no worse than 2A or 2B by tape test < 30 mils of paint (thin film systems) No mill scale or under-film corrosion

THE SPECIFICATION
Work to be done Pre-surface preparation Surface preparation Materials Application Inspection Warranty

QUALITY ASSURANCE
Substrate inspection Ambient conditions Compressed air cleanliness Surface profile Surface cleanliness Mixing and thinning procedures Application procedures Coating thickness Holiday inspection Adhesion

A FOCUS ON UNDERGROUND REHABILITATION USING EPOXY COATINGS

Corrosion, Infiltration and Erosion

Deterioration Underground Structures

Erosion & Abrasion Corrosion from MIC Infiltration

Underground Rehabilitation Entails Difficult Application Environments

Accessibility Temperature and Humidity Moisture Filled Substrates Surface Conditions Structure Condition

Regardless of Technology - Over 80% of All Failures Occur Due to Improper Application

All technologies are installer dependent, including sheet liners, CIPP, fold & form, spray-applied cementitious and polymer coatings Project may dictate installation (downtime, access, condition, etc.) Equipment types are dependent on material

Epoxies for Underground Rehabilitation

Advantages:
- Moisture Tolerant - Fast Setting and Continues Cure Underwater - Ultra High-Build - Good Physical Properties; resilient and tough - Excellent Chemical Resistance - Excellent Adhesion

Disadvantages:
- Require experienced skilled application - Solvent-borne require ventilation and are affected by moisture / humidity - Coal tar epoxies contain carcinogens

Proper Surface Preparation Important Step to Achieve Coating Success

Concrete and Masonry Substrates - Confirm substrate soundness first - Clean and abrade to develop profile and open porosity - Remove contaminants and existing coatings - Stop active infiltration - Use compatible materials

Methods - Low-High Pressure Water Cleaning - Wet Abrasive Cleaning - Abrasive Blast - Secondary methods include acid etching, degreasers, chlorine rinse, etc.

Substrate Profile Determines Coating Thickness

- Industry Accepted Minimum of 40-50 mils DFT for Monolithic Coverage of Smooth Concrete - Substrate Profile After Surface Preparation Determines Necessary Thickness - Structural Rehabilitation Requires High-Strength Polymer and Additional Thickness

Desirable Coating Attributes

Ultra High-Build Quick Efficient Application Monolithic Protection

Structural Repair

Impermeable Corrosion Barrier

Desirable Coating Attributes

NSF/USDA

Moisture Tolerant

Underwater Application and Cure

Excellent Bond

Ceramic-like Finish

The Job is Done When It Passes the Test

Vacuum and Exfiltration Testing
- Used to evaluate integrity of installed materials - Usually performed on manholes and pipelines

Bond Strength
- Used to evaluate strength of bond between coating and substrate - Exposes potential surface preparation errors and product incompatibilities

Spark Testing
- Used to identify holidays or pinholes in coating

THE STEPS TO PROJECT SUCCESS

Conduct a survey to assess conditions, needs and limitations. Develop a comprehensive specification calling for proven materials. Have installation performed by capable and pre-qualified contractors. Assure quality of work by using trained and experienced inspectors.