Wastewater Coating Systems –
In consideration of proven wastewater coating systems, two of the biggest challenges facing concrete wastewater treatment structures are cracking and deterioration of the concrete structure due to chemicals and hydrogen sulfide attack.
When leaks happen, not only do treatment facilities face issues with the EPA and other governmental regulators, but they result in poor performance and face inevitable, costly repairs. The most reliable, protective wastewater coating systems used to protect concrete tanks and structures are advised in this article. “As far as wastewater coating for plants Dynesic epoxy wastewater coating systems have the strongest adhesive strength, submersion properties and contain NO VOCs” according to Scott Phillips, director and technical advisor for Dynesic Technologies “This is a perfect application of our specifically designed products for wastewater treatment facilities”.
“One of the problems with coal tar epoxy is that it’s a carcinogen, so applications for these types of liners involve the need to wear respirators and other safety equipment. This means that the owners of the facility have to worry about workers’ safety and possible compensation claims.”
Additionally, Phillips said, “coal tar epoxy liners need to be applied to a completely dry surface. Other issues include degradation, a lack of chemical resistance protection and the problematic, inherit fact that asphalt based systems have to meat humidity and ideal weather conditions and cannot be applied in sunlight. This means that after a tank is cast and is leak tested, it requires ideal situations once drained and so the material can be applied”.
These restrictions , will have a negative impact due to unknown and realized downtime that can be a detriment to the project budget. As a result, Phillips has been committed to the development of a superior resolution to two new types of concrete coatings for wastewater treatment plants: Dynesic Technologies PANSEAL Abrasion Proof Wastewater Coating Systems and ELASTASEAL Flexible All-Purpose Concrete Coating.
“PANSEAL Wastewater Coating Systems and ELASTASEAL Flexible Coatings are unique, multi-component, modified epoxy coatings that were designed for the protection of concrete, all metal surfaces and stainless steel surfaces in extreme exposure environments. They are designed to work extremely well in wastewater plants,” Phillips said. “PANSEAL and ELASTASEAL share the same beneficial attributes of containing NO VOCs, very minimal odor, HD adhesion strength and optimum weather condition applications while permanently sealing leaks and providing protection against future corrosion”.
They are easy to apply with a brush, roller and can be sprayed as well. Once cured, PANSEAL and ELASTASEAL form a highly alkaline, permanently elastomeric coating that not only protects the concrete and other substrates from water penetration and carbon dioxide diffusion, but also accommodate movement in cracks and joints.”
PANSEAL and ELASTASEAL Wastewater Coating
The main difference between the two coatings is that PANSEAL has 8% elongation which is ideal for abrasion and traffic, whereas ELASTASEAL has a more flexible 300% elongation and it’s rubberized nature is ideally suited cracked substrates, areas of heavy vibration and expansion joints, PANSEAL has an unparalleled 2,750 adhesion strength, while ELASTASEAL’s 1,600 adhesion strength is beyond impressive for flexible coating systems. Both systems can be used to in conjunction on the same wastewater coating project, or can be used alone as an all-purpose wastewater coating.
Primer for Concrete, Wastewater Coating
DX-1100 Wastewater Coating Primer is applied to the concrete structure once the surface is prepared. PANSEAL and ELASTASEAL are designed to self-prime on metal surfaces, but concrete surfaces are unique due to it’s porous nature, vapor (air) moves through concrete surfaces which creates barometric pressure and can have a negative impact as it interacts with concrete coatings. Because concrete surfaces fail due to hydrogen sulfide attack, chemical additives, harsh environments and deterioration, DX-1100 will enhance and strengthen these surfaces.
DX-1100 Concrete Primer for Wastewater Coating is a thin, high strength epoxy designed to penetrate through the pores of concrete surfaces to prevent outgassing issues. When a concrete surface deteriorates, it loses strength and DX-1100 Concrete Repair Primer will reinforce the surface with 2750 psi adhesion strength. DX-1100 can be applied by brush, roller or sprayer at a recommended 3-5 mils per coat (320 to 530 square feet per gallon).
For Wastewater Coating Systems, the concrete must be cured a minimum of 7 days at 75°F (24°C) and 50% relative humidity or equivalent. Prepare surfaces in accordance with ASTM D4258 Surface Cleaning of Concrete and ASTM D4259 Abrading Concrete. Voids in concrete may require surfacing. Mortar joints should be cured a minimum of 15 days. The Wastewater Coating PANSEAL, and/or ELASTASEAL should be applied over the primer within the re-coat window.
Repairing Voids and Absences in Concrete
PANSEAL Paste Grade is a multi-component, novolac epoxy that has a thick viscosity and can be applied with a trowel. PANSEAL Paste Grade vertical surface repair is designed to trowel over surfaces and eliminate sagging or dripping that will occur in applications involving thinner viscosity coatings. Filling voids and absences in concrete requires a thick viscosity that can hold in place vertically and attach to the surface while curing. Once Cured, PANSEAL Paste Grade Surface Repair will strengthen the damaged surface and adhere to the substrate with 2,850 psi adhesion strength. PANSEAL Paste Grade can also be sanded, tapped and machined post cure, as well as be painted or coated over.
“One of the most challenging projects to date was a concrete cooling tower that caught on fire in Houston, Texas in 2012. The severely damaged concrete basin was restored with a combination of DX-1100, PANSEAL and PANSEAL Paste Grade. Not only was the surface repaired and restored, but it was also reinforced and enhanced with the ability to withstand harsh chemicals and environments. The products used for this project will continue to protect the surface and will not degrade over time, even in direct sunlight.
Link to Fire Damaged Concrete Resurfacing Video
Protecting Concrete Surfaces with Dynesic Wastewater Coating Systems
Dynesic, Technologies provides solutions for architects, engineers, and end users throughout the world. Located in Addison, Texas Dynesic continues to create products that seal leaks and permanently protect structures in many industries with the ambition for consistently successful outcomes. For more information about Stealth Materials & Products visit www.dynesic.com or call 972-692-0962.
Chemical attack on concrete can be a devastating result of processing water and wastewater. Coating systems are designed to help protect concrete by providing a barrier to various chemicals, such as sulfuric acid, sodium sulfates, ammonium, an moisture penetration.
You’ll find wastewater coating systems in tanks, troughs, aerators, filter beds, and even clarifiers – pretty much anything that comes into contact with a combination of chemicals or water. There are a number of coating systems proven for water and wastewater treatment applications, but those that particularly stand out are epoxies, coal tar epoxies, polyurea and polyurethane coatings.
Product Data Links
For further questions regarding Wastewater Coating Systems, contact Dynesic Technologies customer support at 972-692-0962