Epoxytec Featured Projects Infrastructure Rehabilitation & Protection

Manhole Rehabilitation: Using the Appropriate Rehabilitation System

2011-07-12T18:27:00.005-04:00

Epoxytec presents...

"Manhole Rehabilitation:
Using the Appropriate Rehabilitation System"

Manholes and other underground structures experience different kinds of corrosion.

Whether it's severe ground water infiltration, high levels of hydrogen sulphide (H2S) gasses, or a combination.

Add to this, budget constraints and specific life expectancy and you have to tailor the rehabilitation solution to match the combination of needs.

They all need to be addressed in their own specific way. One solution does not fit all.

The presentation will discuss, with real life examples, how each one of the different manhole rehabilitation systems can be used to meet specific needs.

REPLAY here

Epoxytec
hosted by: Trenchless Technologies
July 2011

Article: DIY in Florida

2011-07-12T18:19:00.001-04:00

In this article, Epoxytec offers assistance to the City of North Miami via the popular and successful program coined the Epoxytec DIY Program. With this program, Epoxytec guides the City's crew and trains them on-site to tackle a pipe joint project requiring a sealed system to eliminate inflow to the lift station...

DIY in Florida:
North Miami Uses Epoxy & Urethane for Unique Repair

by: Demetri Rapanos
Jun 02, 2011
Trenchless Technologies

Daily Progress - Dec 2010 Issue - Municipal Sewer and Water

2010-12-02T14:16:00.003-05:00

Epoxytec is mentioned in this article of Municipal Sewer & Water for the City of Daly City's manhole rehab program.

Daly City, Calif., pursues a rigorous schedule of sewer televising and repair, backed by a technological edge...

Daily Progress - Dec 2010 Issue - Municipal Sewer and Water

by: Peter Kenter
Dec 2010
Municipal Sewer and Water Magazine

Elko Water Reclamation Facility - concrete infrastructure rehabilitation

2010-11-08T09:50:00.022-05:00

Elko, Nevada - USA, Water Reclamation Facility (WRF)
Concrete Plant Structure Rehabilitation with Epoxy Coating
Epoxytec CPP Structural Epoxy
October, 2010
Certified Applicator: Camino Constructors, LLC.

Wastewater treatment plants are some of the worst environments for corrosion attack on infrastructure. There are many different structures throughout the plant that handle the extreme environment for which waste water is recognized. If not protected properly, this harsh environment will deteriorate the concrete, or steel, over time and cost treatment plants time and money to replace these critical structures.

One of the structures at this facility had been coated previously; however, with the high flow along with the hydrogen sulfide gases from the wastewater pumping into the structure, if not coated properly, or, with the right coating, failure will occur.

Epoxytec, a leader in water and wastewater infrastructure rehab, was called in to consult with Camino Constructors and Elko WRF to provide the best solution for the repair and rehabilitation of this structure. After careful consideration, it was determined that Epoxytec CPP would be the best solution for this project.

Epoxytec CPP is a (2) component structural epoxy with 16,000 psi compressive strength that is highly adhesive, both important for an application of this level where failures have been an issue. The first thing that needed to be done, was to remove the old coating from the structure.

Removing the old coating was done carefully so as not to damage the concrete underneath. This was done by scraping off the coating initially and then grinding what was left in order to achieve a surface to NACE Surface Preparation Standard SSPC-SP 13/ NACE No. 6.

Once the surface was properly prepared, Epoxytec CPP can be trowel applied directly to the cleaned surface. This is particularly important when trying to get the structure back into service with a limited time frame. Epoxytec CPP is a self-priming, re-build and lining system all in one. Another great quality of the CPP is it's ease-of-use and lack of equipment needed to apply. With a drill gun, mixing bit and trowel, you're ready to apply CPP anywhere.

These pictures demonstrate the application procedure for Epoxytec CPP. Once troweled on the substrate, the use of water was utilized to smooth the surface and knock down trowel marks allowing easy clean up of contaminants that may embed themselves into the coating potentially causing damage.

An area of the structure was done immediately after the surface preparation was completed and allowed to cure overnight so that a working area could be utilized the following day without damaging the newly applied coating. In cooler weather, as what we had here, a wall was built on the open side of the structure to prevent the cold air from coming into the building and the use of heat lamps helped moderate the temperature inside the structure so that the product would cure in the proper time and allow for this area to return to service in a minimal amount of time.

Once completed, a final inspection was done to ensure there were no voids or bug holes in the coating and that the coating had cured prior to being put back in service. The total time of application took less than two days to complete and the Epoxytec CPP coating will provide more than adequate protection of the concrete in this type of environment for a long, long time.

Miami-Dade Water & Sewer, SD Influent Pipe - interior epoxy repair

2010-11-04T11:58:00.004-04:00

Miami-Dade Water & Sewer - Blackpoint, FL, USA
Large Diameter Influent Sewer Main
Epoxy Patching & Repair
January 2010

In-house (DIY) crews at Miami-Dade County's Water & Sewer Department access a large diameter influent sewer main pipe for internal concrete and ring repair. The 100% solid epoxy selected for the repair is the Epoxytec CPP.

Recently verified by the EPA-ETV program.

The material provides a hassle free, quick return ability to structurally patch in harsh and logistically challenging environments.

[PLAY VIDEO]
for more videos, visit Epoxytec TV

Escambia County Transfer Station, Tipping Floor - Rehab & Protection

2010-11-01T11:20:00.038-04:00

Escambia County, Solid Waste Transfer Stations
Tipping Floor Repair, Re-topping, and Protection
Epoxy barrier lining with Epoxytec 17G
October 2010
Certified Applicator: Cypress Construction & Coatings, Inc.

Municipal solid waste transfer stations across the world have one thing in common, their tipping floors experience some of the worst corrosion in existence; a combination of ultra-high abrasion and wear coupled with deteriorating chemical attack due to leachate and microbial induced acid, not to mention the assortment of unidentified contaminants to boot. This of course was not different for Escambia County, Florida.

At the transfer station, garbage trucks cycle and constantly dump (tip) mounds of waste onto bare concrete floors, where bulldozer blades push the refuse into bunkers for extraction.

During the process, corrosives saturate the concrete leaving it etched and weakened, while the blades follow through and expedite the wear to the already weakened concrete.

To solve this, solid waste facilities consult with Epoxytec, a leader in tipping flooring system solutions for ultra-high performance repair and rehabilitation.

Epoxytec is the manufacturer of the 17G system, a customized epoxy barrier slab for combating ultra-high wear and abrasion, while sealing and protecting the concrete as a liner against ponding leachate/water and therefore protecting the environment.

The video below demonstrates the typical process of the rehabilitation system:

[PLAY VIDEO]
for more videos, visit Epoxytec TV

The Epoxytec 17G system was selected as a sectional system for this project to be installed on half the floor in 2010, and the other half later in the near future. For this blog, the first half is documented.

To successfully apply the system as a sectional liner, an undercut was created into the existing slab to provide a flush transitional point of termination, so the that the dozer blades do not chip a high exposed edge, but rather make a flush approach.

After creating the key way, undercut, the floor then needed to be prepared. The Epoxytec certified contractor utilized an Ultra-High Pressure Water Jetting rig to blast. The UHP equipment not only blasts and etches concrete, but also rids all contaminants with 40,000psi of water, enough to cut granite.

The UHP method is practical and effective, as it cleans and blasts all-in-one-shot. Attached is an optional "floor hog" add-on for blasting while overspray is being contained in a vacuum environment, therefore debris doesn't effect the surrounding crew or equipment.

The picture below demonstrates the awesome nature of the blast, leaving a noticeable, clean and etched surface, ridding all loose concrete and removing all contaminants by deep and high pressure extraction. Doing this provides a surface to NACE Surface Preparation standards, SSPC-SP13/NACE No.6.

After blasting, the crew worked throughout the evening and rinsed with ultra-high temperature, high pressure water blasting to further rinse and clean via deep penetrating steam.

After the surface prep was completed, the rinse exposed a medley of cracks throughout the floor surface. To navigate through this setback, the experienced crew knew they needed to level these cracks before applying the 17G system. Using the resin-mix of the 17G with a small ratio of aggregate filler, provided a consistent slurry mix to fill the cracks in before application.

The cracks appeared in all sizes.

Being the the cracks were caused from unknown reasons, the system had to address the potential of movement. Therefore, the crew decided to utilize fiber-mesh within the slurry filler to combat and bridge any unforeseen movement that may occur in the future.

Using fiber-rolls, the material was laid on top of the 17G resin filler and crack.

After which, the 17G resin was applied to embed the fiberglass.

Before applying the system, priming was specified to assist in any out-gassing or and water vapor transmission (MVT) that may occur. Using the Epoxytec B2 Primer, a water-based epoxy primer, ensures the proper sealing of moisture and out-gassing before application of the epoxy 17G system.

The entire surface of the tipping floor to be lined by 17G is coated first with the B2 Primer. This waterborne primer has no VOCs, indicates top coating readiness when it turns clear, and penetrates deep into the concrete surface crosslinking with the existing moisture, as it is itself, water-based. Once cured, the B2 Primer provides a the chemically sealed adhesive enhancement with a glossy finish to facilitate the application and glide for the top liner.

Once the primer is initially cures, the application of Epoxytec 17G can begin. The 17G is a highly filled, 3 component, trowel-grade epoxy liner, and when applied and cured provides anti-abrasive wear resistance with incredible compressive properties of 17,800psi. The highly dense material cured to a heavy, epoxy slab like top liner which also provides chemical resistance and sealed barrier lining.

To get started with 17G, mixing logistics must first be organized and decided upon. Typically, the material can be mixed in a pre-proportioned kit with a power drill. However, for large job, a mortar mixer provided a more efficient method of mixing in volume.

Once mixed in volume, the material was transported with a simple hand cart and then poured onto the surface. The material needed to float, ultra-high build at a least 1/4" - 3/8". Some floors, depending on the profile may even require more, such as 1/2" - 1 inch. For this project, the 17G was applied between 3/8" - 1/2" in some areas.

Utilizing a pour-and-spread method, certain tools benefited the application crew well. These tools included an assortment of trowels and pin rakes. The 17G material, although trowel-grade, has an ability to blend in well, as the top surface does settle a bit to help alleviate minor inconsistencies.

The project was completed in 3 days, and was returned to service after 24 hrs. The total square footage was circa 5,500 sq.ft.

Final installation:

Epoxytec 17G System
3/8" - 1/2"
3 days
Manufacturer - Epoxytec
Certified Contractor - Cypress Construction & Coatings

Storm Drains & Culverts, NAS JAX - concrete rehab and epoxy lining

2010-10-18T14:35:00.020-04:00

Naval Air Station Jacksonville (US Navy) - Jacksonville, FL, USA
Structural Epoxy Rehabilitation & Lining
May 2008
Certified Applicator: Engineered Lining Systems

Epoxytec product solutions were approved for rehab and lining of box culverts, catch basin vaults, and storm drains at Naval Base - NAS JAX by a certified contractor.

The first part of the project's scope was to remove compromised existing liners, of which included a cured in-place liner.

Following the removal of the existing liner, the underlying concrete was prepared to SSPC-SP13/NACE No. 6.

Some areas of the concrete required a quick mortar rub down for filling large voids in preparation before the epoxy liner. Using a quick cure, hydraulic cement, such as Epoxytec Hydrxx-3, would provide the right properties and cure time.

The liner chosen for the rehabilitation and corrosion barrier was the Epoxytec CPP lining system. 2-part, epoxy liner for filling, coatings, and restoring concrete.

The CPP is a trowel-applied epoxy, once cured, provides corrosion resistance, stops I&I, and restores concrete to an original profile with structural 16,000 psi compressive strength.

CPP provides crews a perfect lining system for limited access areas requiring minimal blasting to prevent airborne dust, and a safe environment to work with zero VOCs.

When completed, the concrete was repaired, strucutrally reinforced, resurfaced and lined all-in-one-shot with 1/8" (125 mils) of Epoxytec CPP.

Plugging the Gaps - July 2010 Issue - Municipal Sewer and Water

2010-08-06T14:10:00.009-04:00

A good read . . . Epoxytec featured in Municipal Sewer & Water. This article is about how Miami-Dade Water and Sewer Collections Division is saving money, creating skills, and rehabilitating manholes in-house with an economical long term program.

Plugging the Gaps - July 2010 Issue - Municipal Sewer and Water

by: Scottie Dayton
July 2010
Municipal Sewer and Water Magazine

Rehabilitation of Lift Station, North Miami Public Works Department - concrete lining

2010-04-30T10:38:00.034-04:00

City of North Miami Public Utilities Department- North Miami, FL, USA
Structural re-build of concrete with calcium aluminate mortar with an epoxy lined top coat.
March 2010

The City of North Miami and Epoxytec co-consulted to determine a solution for the concrete rehabilitation of one of the City's many lift stations. Lift stations are used to raise the waste water up to a level that will allow it to gravity feed into the sewer line. Because the waste water builds up over time in the wet well before it is pumped down, the H2S gases and waste take its toll on the concrete of the lift station causing extreme deterioration. This deterioration can cause structural failure and potentially lead to leaks and exposure to the environment.

If the concrete is not protected properly, the gases in the form of hydrogen sulfide will completely corrode and destroy the concrete. This extreme environment has to be taken into consideration to determine the best coating system necessary to combat the effects of corrosion. Epoxytec offers free consultation for their clients who may not understand these factors and will always help to find the best solution for their clients needs.

In this instance, the concrete required a complete structural re-build and then needed lining with a high performance epoxy liner. For the re-build, Epoxytec suggested a calcium aluminate mortar, Epoxtec Mortartec Aluminate, which is a high density sewer grade mortar that provides an added layer of protection to the underlayment in the event the underlayment is exposed in the future. It also proivdes a solution where the existing structure requires enhancement of 10,000psi plus compressive structural integrity for resurfacing or rebuild.

Surface preparation is always important for any coating application. The substrate must be completely rid of poor concrete and contaminants that might have settled in the concrete. This surface was prepared by sand blasting to NACE No.6/SSPC-13, which removed all contaminants and gave the concrete an ideal profile to coat over.

Once completed, Epoxytec's Mortartec Aluminate can be troweled or sprayed onto the surface, depending on the contractor's capability. The contractor here, sprayed the Mortartec Aluminate for a build up of nearly 4" in some spots where the rebar was exposed. In order to build up that high, the mortar needed to be sprayed in 2 passes, another one after the first coat cured in approximately 12 hours.

Although the calcium aluminate can be used for a back-up protective layer, Epoxytec encourages a higher performance liner should always be utilized. With the presence of such high amounts of hydrogen sulfide and contaminant build- up in lift stations, Epoxytec suggested the use of Epoxytec Uroflex, which is a proven urethane-modified epoxy liner used for immersion in such environments that will help with premium protection for the top lining. The Uroflex, because of its urethane finish, will also be easier to clean when dealing with grease build-up concerns. The high gloss of urethane will allow any build up of contaminants such as fats, oils and grease to be easily removed with your everyday pressure washer.

To replace a structure of this size just wasn't an option within budget, but with the help of Epoxytec, a budgeted and improved solution of trenchless rehab would provide more than adequate protection from gases and allow for easy clean-up for future evaluations and repairs that may be needed in this lift station. This coating system will protect the concrete for years to come and provided the City of North Miami with a money saving solution that will allow them to continue their efforts in maintaining their underground infrastructure in order to prevent major complications from happening in the future.

Accelator Clarifier Rehabilitation, City of Pompano Beach - steel rehab and coating with NSF Certified epoxy

2010-04-13T09:13:00.041-04:00

City of Pompano Beach Utilities, Water Treatment Department - Pompano Beach, FL, USA
Structural re-build of steel with an epoxy paste and coated with a urethane-modified epoxy
January, 2009

The City of Pompano Beach consulted with Epoxytec to come up with a solution for the repair of their Water Treatment Plant's Accelator Clarifier. The severity of the corrosion that has taken place on the steel left the question; can this water clarifier be repaired or will it have to be replaced?

After careful consideration of time, budget and products, the City of Pompano Beach and Epoxytec came to the conclusion that this Accelator Clarifer could indeed be rehabilitated to its original form and better.

Epoxytec helped the Pompano Beach Utilities Department write the specification for the steel rehabilitation of the potable Accelator Water Clarifier as is typical in many instances to provide free support for our clients that are unfamiliar with coating requirements and specification needs. These specifications were designed for steel coating per SSPC and NACE standards.

After the specifications were completed, the next step in the process was selecting a contractor to perform the work. Epoxytec has a network of certified contractors which are also SSPC and NACE certified, that can bid on coating and rehab projects which allows us control quality assurances and serve the warranty without having to inspect the project on a constant basis. This also allows the City of Pompano Beach to go about their daily business and let Epoxytec manage the project for them which is another service provided if requested.

The City of Pompano Beach utilized an active annual, itemized contract that allowed them to price the project per square foot. This process saved time and streamlined the start date earlier to prevent any more deterioration to the steel structure and avoid the spring season (rainy season).

The Accelator Clarifier uses turbulence by a rotor-impeller, and chemicals to treat the water that allows for the separation of sludge and contaminants from the water. This process, as you can see, takes a massive toll on the steel structure and would eventually be in need of a high performance coating that could handle this environment and also be able to combat U.V. that damages coatings exposed to outdoor environments.

After dry abrasive blasting in accordance to Nace No. 1/ SSPC-SP 5, "White Metal Blast," an Epoxytec representative inspects the surface, as part of their agreement with City, and the patching and re-building process can begin. The surface preparation crew did a terrific job in getting the steel to where it needed to be in order to properly rehab and coat the steel.

Due to the fact that the steel had many holes and was on the verge of replacement, Epoxytec suggested the use of a structural epoxy paste to patch any holes and re-build any areas that may have weakened from the corrosion. Epoxytec's epoxy filler is a 1:1 ratio, epoxy paste mix that has a compressive strength of 16,000 psi which bonds to steel extremely well. It's a smart patching material because you can mix as much or as little as you need depending on the amount of surface needing repair.

Once all the steel is repaired and primed, Epoxytec conducted another inspection for the City to determine the acceptance of the coating system. Once the steel structure is deemed suitable, the coating now has to be installed to prevent future corrosion and assist in buildup of lime and calcium.

Corrosion is inevitable in these environments and it is crucial to pick the the right coating for the right environment. Epoxytec Uroflex 61 was determined to be the best solution for this application. Uroflex 61 is a urethane-modified-epoxy (UME) that has great chemical and abrasion resistance as an epoxy, which is well suited in this type of clarifier as it aslo has great UV resistance due to its urethane finish. It is also a 1:1 mix ratio and can be applied by spray, brush or rollers. This allows applicators to choose the best way to apply considering all logistics of their environment.

Once completed, the steel structure is rehabilitated to its fullest and will be protected the proper way from the harsh environment inside the clarifier to the harsh environment outside the clarifier.

This rehabilitation process that Epoxytec recommended, utilizing epoxy restoring compounds and Epoxytec Uroflex 61, allowed the City of Pompano Beach to save hundreds of thousands of dollars in having to replace the Accelator Clarifier in its entirety and instead a newly rehabilitated and improved structure was delivered with simplicity and budget consideration.

Main Influent Pipe Lining, City of Tampa - lining with structural epoxy at pipe bends

2010-03-22T11:23:00.034-04:00

City of Tampa, Wastewater Department - Tampa, FL, USA
Pipe lining, concrete repair and rebuild - hand-laid sectional and structural epoxy pipe liner at the 90 degree bend.
Howard F. Curren Advanced Wastewater Treatment Facility
March 2010
Epoxytec Certified Contractor: Vac-Vision Environmental, LLC.

Certified contractor, Vac-Vision Environmental paired with Epoxytec to assist in a pipe lining project for Insituform Technologies® and the City of Tampa at their Howard F. Curren Advanced Wastewater Treatment Facility. The main influent pipes, 72 inches in diameter, have the capacity to bring in 96 million gallons of wastewater per day. With this kind of high erosive flow and chemical corrosive attack of the concrete, there is no doubt a high performance liner would be needed in order to rehab, improve, and protect the structure in this environment.

A number of considerations go into a product recommendation for this kind of project. For one, the scope needed to be understood in its entirety considering that Insituform needed to approve the Epoxytec solution as a tie to their in situ sewer-grade CIPP (cured in-place pipe). At the 90 degree bend in the pipe, the Epoxytec material had to be proven to bond unquestionably well to the CIPP liner that was planned to be inserted. In addition, the material needed to be structural, and intended as an in situ sectional liner to monolithically compliment the entire CIPP liner.

Therefore, accessibility, ease-of-application, bond strength, structural/modulus properties, the "tie-in" factor, and the environmental and anti-corrosive protective attributes are just a few examples of some of the evaluating data reviewed. Epoxytec suggested the use of Epoxytec CPP and Epoxytec Uroflex. Both are 2-component, 100 % solids epoxy with no VOC's (Volatile Organic Compounds) that are ideal for confined space and hard to reach areas, such as this application.

With easy-to-use and uncomplicated logistical application methods - the material and tools were simply lowered into the opening approximately 30 feet below the surface and then carried almost 300 feet down the pipe where most of the work actually took place.

The straight sections of the pipe lining was completed by Insituform Technologies® using their proven CIPP liner; to faciliate a monolithic system at the 90 degree bends of the pipe, Insituform consulted with Epoxytec for a sectional complimenting lining system.

The solution that would "tie-in" to the CIPP liner was Epoxytec CPP. The CPP epoxy is the perfect solution because its adhesion is remarkable, especially to concrete and other materials with little preparation and it has a structural compressive strength of 16,000 psi.

Exterior and interior photo of the 72" rehabilitated pipe.

High flow rates and H2S attack pose a threat to wastewater pipe lines on a continual basis. Not only does Epoxytec CPP perform against these threats, but the ease of application plays a big role as well. Epoxytec CPP can be mixed by drill, troweled onto the surface and can be applied to 100% moisture saturated surfaces; ideal for underground water pipes that are inaccessible for the most part.

To further combat against deterioration of the pipe, especially at the seams, Epoxytec Uroflex was utilized for its extreme chemical resistance and its flexibility to allow for movement of the pipes. At the seam, anticipated movement will be bridged with Uroflex because of its 38% elongation feature. This product can also be mixed by drill, applied by brush or roller and "ties-in" to Epoxytec CPP as if it were one unit system.

When completed, a uniform coating on the laterals and into the bends was achieved. This will ensure the pipe is completely sealed and that there are no breaks in the coating along the entire pipe, an important aspect of a main influent pipeline repair that it needs to be repaired and lined in one shot.

Wastewater Clarifier Trough Rehabilitation, City of West Palm Beach - concrete resurfacing and coating

2010-02-06T22:20:00.027-05:00

City of West Palm Beach, Public Utilities - West Palm Beach, FL, USA

Concrete repair, rebuild, and coating of clarifier troughs (#1-#8)

East Central Regional Water Reclamation Facility

2009 - 2010
(Epoxytec certified contractor: Service Painting of Florida)

The City of West Palm Beach consulted with Epoxytec to assist in the design of a proper specification for the rehabilitation of concrete wastewater clarifier troughs.

Outdoor concrete troughs require restoration at times, and must include the utilization of high performance coatings to combat the effects of corrosion.

Although most wastewater clarifiers, especially those found in the secondary process, do not typically pose a threat due to high chemical attack, such as sulfuric H2S, they do however come with a variety of other considerations to address. Because of the ultraviolet rays coupled with treated sewage or reclaimed water beating down onto porous concrete - breeding of excessive algae is a constant issue. Algae roots into the concrete, deep and annoyingly. When attempts to remove the excess microbial growth, often times maintenance crews find that chunks of concrete comes out with it. In time, the algae and continuous water trickling through the weirs begin to erode and weaken the concrete binder.

Prior to any rebuilding or coating, the concrete must be assessed and prepared. To avoid any sand entering the clarifier itself, and possibly harming the pumping operation, water blasting was specified via the use of ultra-high pressure water jetting (UHP).

UHP water jetting not only removes all the algae; at 40,000 psi, the ultra-high pressure water also removed any previous coatings, eliminated all loose or weakened concrete binder and aggregate, etched the concrete, and cleaned/decontaminated all-in-one-shot.

Concrete should be clean, sound, and etched before applying any reparative or protective materials.

As per NACE and SSPC standards, follow-up inspection after blasting is highly encouraged. Here a NACE/SSPC certified inspector checks the pH level in the concrete after blasting to ensure neutral to alkaline concrete has been exposed after blasting. This is one method to gain confidence that decontaminated concrete has been eliminated, for wastewater corrosion typically keeps the contaminated surfaces acidic, and therefore that acidic surface most be removed.

The selection of a high build, ultra-high density mortar was specified - Epoxytec MortarTec Silicate.

Epoxytec MortarTec Silicate is a perfect selection for this project because it provides the applicator the right amount of pot life to mix and trowel, yet it is designed for top coating as it cures within 24 hours without harmful curing agents often problematic to top coating, and to a density near 10,000 psi compressive strength in a matter of a hours.

Mortar had to be utilized in this application, because the concrete was so badly deteriorated by the rooting algae that large aggregate was exposed leaving a near impossible substrate to coat without a resurfaced underlayment.

After troweling the mixed resurfacing mortar, a 24 hour cure was required before protective coatings were applied.

After the final cure of the Epoxytec MortarTec Silicate, a light water blast took place to remove any laitance or dust. With a uniform and resurfaced profile and filling of any bugholes or voids, the surface can now be coated.

Before coating, the City specified Epoxytec CPP Gel to fill and seal between the mortar rebuild and the original clarifier weirs, as a highly adhesive joint sealant to anchor the weir and fill the gap.

The coating is now applied, Epoxytec Uroflex (urethane-modified-epoxy) coating system for wastewater (with algae and chemical resistance exhibiting self-leveling properties, UV tolerance, high gloss, and flexibility).

The Uroflex coating is a great option for confined places or areas difficult to mobilize. Because it can be rolled or sprayed it offers an application crew options and various mobilization logistics depending on this situation.

Because the Uroflex is an epoxy, but modified with urethane it gains an ultra-high glossy sheen because of the urethane, making the surface (even after cure, as it is seen here) a very non-porous, smooth and leveled top coat in order to prevent algae from rooting. And therefore it also facilitates any cleaning methods the plant so chooses, whether brush sweepers or chlorinated spray - it will withstand and assist the algae cleaning effort with no rooting making it easy to come off and controls the algae from growing excessively, aggressively or long.

The Epoxytec Uroflex coating is also suitable to the outdoors, unlike other epoxy-only systems. Ultraviolet (UV) is known to breakdown epoxies, however, because Uroflex has urethane modified within its matrix, it is UV stable and does not degrade in an outdoor immersed environment such as in clarifier troughs and therefore, stays impermeable and durable throughout its life expectancy.

The coating system is repairable, never looses its recoat window and can be applied in multiple lifts because of it. Here we built a 60 mil system. The mileage was selected high build enough to properly fill and cover all the peaks and valleys of the substrate, yet stay semi-structural, allowing a durable liner with enough movement and flexibility to conform with the outdoor expansion and contraction requirements. Uroflex has 38% elongation, unlike typical 1% - 6% of solid epoxies.

After holiday testing (spark testing) was completed, a final visual inspection was conducted and signed off. The warranty was delivered to the owner, backed by Epoxytec and their certified applicator.

The installation of clarifier trough renewal systems and protective coatings was successful.

Resurfacing: Epoxytec MortarTec Silicate @ 1/2" - 1"
Weir anchoring and sealing: Epoxytec CPP Gel
Coating system: Epoxytec Uroflex @ 60 mils

Manhole Chimney Seals, Kentucky Horse Park- Rehab with Structural Epoxy Coating

2010-02-02T13:26:00.030-05:00

Kentucky Horse Park, Fayette County Utilities - Lexington, KY, USA
Epoxytec Certified Applicator: Municipal and Contractor Sealing Products, Inc.
Rehabilitation and sealing of concrete manhole chimney with structural epoxy paste.
January, 2010

Epoxytec and their certified contractor were called upon to rehabilitate some manhole chimneys that were corroding and leaking. The area of the chimney can be a tricky part to rehab as there are typicall many active leaks to deal with, as well as, movement from the ground and freeze/ thaw.

Manholes at the Kentucky Horse Park are not always easily accessible, as you can see below, and rehab can be difficult. Epoxytec suggested a product that uses little mobilization, that's easy to use and also works in such a harsh environment. Epoxytec recommends that Epoxytec CPP be utilized, it is the best product for this type of application.

Epoxytec CPP is a two component structural epoxy paste. It is a moisture insensitive, highly adhesive 100% solids epoxy with no Volatile Organic Compounds (VOC's). After hydroblasting all loose and contaminated concrete, a mortar was applied to cover any major voids in the concrete and give a sound substrate for the Epoxytec CPP to be applied.

Epoxytec CPP comes in two part kits which are easy to transport. It also needs very little tools to mix and apply. A drill, mixing bit, trowels and some water are about the only things necessary to apply this product which makes Epoxytec CPP ideal for this application.

Once the Epoxytec CPP is troweled onto the substrate, it can smoothed down with your hand and water to give it a nice smooth finish. Not only does it look good, this type of finish helps prevent build up of contaminants on the walls that could enhance corrosion of the substrate.

Epoxytec CPP is great for sealing chimneys as it has the perfect balance between compressive strength, flexibility and adhesion in which most other epoxies would fail.

UV Chambers, College Station Utilities- protective coating of concrete

2010-02-01T08:36:00.041-05:00

College Station Utilities, Waste Water Treatmant Plant

College Station, TX, USA

Coating concrete with high performance, protective epoxy modified liner

January 2010

The final step before treated wastewater can be released back to the environment is disinfection. College Station's wastewater is disinfected with ultraviolet (UV) light. Not only is UV light safe, it also disrupts the genetic material of disease-causing organisms, preventing the organisms from reproducing and spreading disease. The lights are installed, wall-to-wall, in two sections of a chamber that the water flows through so that no water can pass without being treated.

The chambers are formed from concrete and must be coated in order to prevent corrosion and spalling from the UV lights and waste water that passes through. The previous coating on these chambers had been almost completely deteriorated and needed to be removed entirely so that a new coating could be applied. After water blasting the surface using a 5000 psi pressure washer with a turbo nozzle, the substrate was cleaned, dried and ready for the coating of Epoxytec Uroflex.

Before the lining system gets installed. The utilization of the Epoxytec B2 Primer was applied to prevent excessive off-gassing of the concrete and to reduce the risk of pin holing.

Epoxytec Uroflex, a urethane-modified-epoxy that has a high gloss finish, was chosen for this application because of its superior protection against ultraviolet light and it's tolerance for high levels of moisture without failing.

In the pictures above, some of the larger spalled areas of concrete were coated over with Epoxytec CPP Gel. This is an epoxy-based gel that is a 1:1 mix used for filling, patching and re-build that also helps combat corrosion.

Epoxytec's certified applicator did a great job with surface preparation and application of Epoxytec Uroflex by using the equipment, knowledge and expertise for doing the job right way. The application of Epoxytec Uroflex started on the walls of the chambers and was done in two passes of 25 mils each to meet the specified requirements of 50 mils.

Epoxytec Uroflex can be applied in a variety of ways. For this application the use of paint brushes and rollers was utilized for an "easy-to apply" method, however; this coating can be spray applied as well.

Once the first coat was applied to the walls, the certified applicator dealt with some out-gassing of the concrete as shown in the pictures below. To combat this gassing, Epoxytec CPP Gel was used to coat over the areas of concern and seal the "bug holes" from out-gassing anymore. Once complete, the second coat of Epoxytec Uroflex was applied to the walls.

Once the walls were coated, the work on the floor began. The floors were swept over to ensure there were no contaminants and then Epoxytec Uroflex was applied. The floor was coated in one pass at 50 mils.

When finished, the Epoxytec Uroflex has a gloss shine which helps protect from algae build-up and UV Light damage. Once the product cures, the next day, the UV Lights can be installed and the chamber can be put back in service.

This was the crew's first application with Epoxytec Uroflex and they finished the coating of this chamber in three days from beginning to end. Once this chamber was put back into service, they started on the next chamber. The certified applicator finished the second chamber, from surface preparation to finished product, in one day and put back into service the next.

SDA Penthouse Floor & Washdown Trench, Solid Waste Plant, Wheelabrator South Broward - steel floor rehabilitation and protection

2009-08-29T16:14:00.039-04:00

Wheelabator S. Boward (a Waste Management company) - Hollywood, Florida, USA SDA Penhouse & Washdown Trench floor rehab and coating
(performed by an Epoxytec certified applicator)
2/17/2008

At many solid waste facilities, you'll find scrubber penthouse areas. These areas are commonly referred to as the Spray Drier Absorber (SDA) Penthouse, which houses lime slurry, muriatic acid and dilution water, and atomizing air distribution equipment and spray nozzles.

Corrosion is a commonly problem many refuse processing plants have to deal with. The floors are typically made of carbon-steel, often in layers with non-skid checker-plates surround by metal siding. This steel alone is susceptible to rusting, but the corrosives forces are accelerated when chemical attack becomes catalytic from lime and muriatic acid. In fact, these floors are further burdened with washing cycles, constantly. The constant etching effect of corrosion takes its toll on the floors, and steel is lost; this lime builds a corrosive polish leaving the floor hazardous to slip and accidents.

Not only does corrosion put a financial burden on the Owner, but its also leaves an unsafe, slip prone surface as well.

Leaving the floor to continue on its corrosive course will ultimately effect the surrounding areas as well. Muriatic acid and other corrosives can make there way around the exterior penthouse sidings, and possibly accelerate corrosion around the joints to the floor and SDA lagging and SDA vessel itself.

After abrasive blasting to SSPC SP-10/NACE No. 2, the floor was repaired and all steel cavitation and pitting was filled with an epoxy metal filler by Epoxytec. The epoxy steel filler, is a high performance epoxy paste to reclaim metal and fill.

To prevent flash rusting, an Epoxytec epoxy primer designed for steel was utilized. The primer is a steel epoxy primer/coating with friendly recoat capability.

The top coat recommended was the Epoxytec BlackMac. The BlackMac system was formulated for ultra-durability, and as a high build performance coating. It has incredible bond strength, good elongation to bridge vibration and expansion/contraction, and it's easy to apply.

The BlackMac coating emits zero VOCs, zero fumes, and no solvents; making the 100% solids material very friendly to the environment, workers, and safe to use around the high heat of the surround processing structures (ovens).

The BlackMac flooring system is also repairable. Unlike many coatings, as they score or compromise, they typically fail around the compromise at an accelerated pace. The BlackMac however, does not act this way, in fact, simple repairs can be made indefinitely with no major equipment, no excessive preparation - simply use a wash rag with degreaser and mix a few ounces and touch-up by brush.

This system was applied at 2 x 30 mils, for a total DFT of 60 mils. "Black Beauty" granules were broadcasted on the second coat for slip resistance, making the final system non-skid.

A NACE coating inspection was made one year later - with zero compromises and no need for any touch-up nor repair.

City of Hollywood, FL In-house Manhole Rehab Using Epoxytec CPP

2009-08-24T14:15:00.020-04:00

City of Hollywood, Underground Utilities - Hollywood, FL, USA
Trowel-applied, Structural Epoxy for use in manhole rehabilitation
July 2009
Epoxytec DIY Program - municipal

In August 2009, Epoxytec met with the city’s crews on site to begin the training and rehab of two manholes. Prior to this, Epoxytec had given a training demonatration at the city's warehouse, much like was featured on the Rockdale, GA blog.

Upon arrival we gave the utility maintenance crews a short refresher on the Epoxytec CPP and its application, after the manhole had been water blasted and prepared. Emphasis was placed on the "green" aspects (100% solids - no solvents, no VOC's), ease of use (cold trowelable) and forgiveness (can be applied to 100% moisture saturated concrete and cures under water).

City of Hollywood crews preparing manhole with water blasting.

Prepared manhole ready for coating with Epoxytec CPP.

The initial training and application was done using Epoxytec CPP Gel. The product can be mixed up in a one-to-one ratio by volume and can be used in small quantities, making it ideal for training purposes. Epoxytec CPP and CPP Gel can be used as a one coat liner and rebuilder. The product is 100% solids and therefore seals exceptionally well. Added to that, its 16,000 psi compressive strength makes it ideal for a structural rebuild.

Epoxytec CPP Gel - a one-to-one by volume 100% solids cold trowelable epoxy.

Members of the crew took turns applying the coating to the walls and bench of the first manhole with Epoxytec CPP Gel. Epoxytec recommends application at 1/16 of an inch DFT as a minimum application thickness for this product. The initial application included coating part of the bench, a section of the wall and the chimney of the manhole. This would allow the crew to return after the product cured, and stand on the completed portion of the bench and coat the rest of the manhole.

In-house crew member from City of Hollywood, FL applying Epoxytec CPP in manhole.

First Manhole at the end of Day 1. Partially Coated with Epoxytec CPP Gel.

The second manhole was then prepped and cleaned. As long as concrete is sound Epoxytec recommends a minimum 5,000 psi water blasting for application of CPP or CPP Gel. This manhole had a lot of very rough brickwork on the chimney. This brickwork needed to be resurfaced with Hydraulic Cement. This was done for the sole purpose of minimizing the amount of epoxy that would be needed to coat this area.

Second Manhole: Rough brick surface is very evident.

After Resurfacing with Hydraulic Cement: Ready to Coat

On day two the crew arrived on site and began with the task of finishing the first manhole that was partially completed on day one. Epoxytec CPP and CPP Gel tie into each other and themselves indefinitely. There is no recoat window. Within a short amount of time – less than an hour – the first manhole was completed, and the crew was ready to move on.

First Manhole Completed: Lined with Epoxytec CPP.

After a small batch of CPP Gel was used to get comfortable with the work environment, we then started mixing up 2 gallon kits of Epoxytec CPP. It is identical to the CPP Gel and also comes in a 2 gallon kit. The two gallon kit, however, has to be used up in one shot and is ideal for larger areas once crews are comfortable using the product.The crew then applied two consecutive kits of Epoxytec CPP onto the surface of the manhole and lined the entire structure. The lining took approximately one and a half to two hours to complete.

Second Manhole Completed with Epoxytec CPP.

In conclusion:

The crew did a very good job on their first attempt.
The second manhole was a very good indication of what to expect going forward.
For a typical 6’ Manhole:

A crew of 3-4
Power washing and prep (approximately 20 minutes)
Set up all equipment while surface dries (30 minutes)
Resurface any exceptionally rough areas such as brick with Hydraulic cement (Used 4 kits to do entire chimney area - approximately one hour)
Once mortar has cured, apply 2 kits of CPP (Approximately 1-2 hours)
Put manhole cover back on and return to service

Approximate time: 3-4 hours

Cost of two kits of Epoxytec CPP: ($230.00 x 2) = $460

Hydraulic Cement price unknown (supplied by City)

Junction Chamber, City of Tampa Wastewater Department (Tampa, FL, USA) - epoxy concrete repair & patch liner

2009-08-13T14:01:00.037-04:00

City of Tampa, Wastewater Department - Tampa, FL, USA
Trowel-applied, Structural Epoxy - for use in concrete repairs and as a sectional liner (T-Lock tie-in)
Howard F. Curren Advanced Wastewater Treatment Plant - JC1
August 11, 2009
(certified contractor: Service Painting of Florida)

The City of Tampa invited Epoxytec and Service Painting of Florida (certified Epoxytec applicator) to the Howard F. Curren Advanced Wastewater Treatment Plant to conduct testing and inspection of Junction Chamber #1.

A visual inspection of JC-1 revealed a corrosive discovery affecting the concrete structure and the previously installed mechanical liner (T-Lock).

To demonstrate and evaluate a sectional liner tie-in recommended by Epoxytec, an area of the T-Lock was removed.

The existing T-Lock liner was fairly loose and losing anchoring capabilities to the concrete. After years of service it is determined that most of the area should be inspected to identify all areas that are compromised.

Considering the "T's" (anchors) were somewhat compromised and that the concrete behind the liner was degraded from sulfuric attack - removing the liner material by blade and hand (peeling) was done rather quickly.

After removing a vertical strip of T-Lock, the exposed concrete behind it proved to have been attacked by Hydrogen Sulfide's (H2S) microbiological sulfuric byproduct. The sulfuric acid accumulated, in concentrate behind the liner and therefore deteriorated the concrete at an accelerated rate as compared to the concrete below the water line.

Above - the peeled section of the T-Lock.

The concrete section that was targeted for rehab evaluation was prepared utilizing 35,000psi UHP hydroblasting.

In addition to hydroblasting, the edges of the T-Lock remaining were top-anchored with metal termination strips.

The prepared concrete section was recommended to be rehabilitated and sectionally lined with Epoxytec CPP. This sectional evaluation will demonstrate a 100% solid trowel-on epoxy to rebuild and line in a one-shot application in order to minimize downtime for a speedy, 1-step application.

In addition, the material is designed for extreme bond strength to many materials, such as at the termination strip of exisisting liners, such as in this case - T-Lock.

The Epoxytec CPP is recommended in addition to the other benefits also because this chamber was left with water (sewage) in it, pumped down. CPP cures on saturated surfaces, and therefore is moisture tolerant. This makes the material a prime selection in logistically challenging environments, such as in this case - where concrete is saturated, adhering to previously installed liner is a requirement, and when resurfacing and lining need to be applied in one-application.

The versatility of Epoxytec CPP for patching, sectional, repairs, rebuilding, and as a 100% epoxy liner can be observed on this project. The material is structural and cures with an impressive 16,000 psi compressive strength.

In the hands of an experienced applicator - the material is applied in short time.

After the material is applied in total thickness - it is then back-rubbed with water to knock-down all trowel marks, making the final coat consistent and smooth.

In hot sunny conditions, this structure could be returned to service in about 1-hour after the application. The Epoxytec CPP system (if applied in shade or at night), if needed, could be heated with hot air to force cure it faster depending on the requirements of the Owner.

Total DFT: 1/8" - 1/4" (125 mils - 250 mils).

Solid Waste Tipping Floor, Push-Walls - Wheelabrator South Broward - concrete restoration and rehabilitation

2009-08-09T19:28:00.055-04:00

Wheelabrator South Broward (a Waste Management company) - Hollywood, Florida, USA
Transfer Station / Tipping Floor, Push-Walls
(performed by an Epoxytec certified applicator)
9/18/2008

Many waste management facilities face deteriorating problems surrounding their tipping floor structures. In particular, the transfer station push-walls experience a lot of abuse. These constructed cushions in the tipping hall are typically made of concrete, and are designed to absorb impact and wear as refuse transfers from truck dumps to the pit for processing. Often times, the trash builds and slides against the walls as it is pushed to the refuse pit. The transferring mechanism typically consists of bulldozers, which in turn score and push solid waste onto these concrete walls, hence the name - push-walls.

The level of deterioration seen in the above pictures captures the intensity and incredible force of the scoring nature of highly abrasive and wearing solid waste. Discarded trash items both chemical in nature and often time large (such as refrigerators, sofas, trees, metal components, etc.) are constantly tearing apart and spalling chunks of concrete from the push-walls.

The spalling forces are so extreme that inches of concrete deteriorate and leave critical exposed reinforcing bars (rebar) vulnerable to further accelerated corrosion.

A customized material formulated to combat this problem was created by Epoxytec for Wheelabrator, but before installing the product, surface preparation using Ultra-High Pressure (UHP) waterjetting had to remove all unsound and contaminated concrete per NACE No.6/SSPC SP-12 standards. After which form frames must be installed.

The material utilized was Epoxytec 17G. The material has incredible bond strength with the ability to thin-out at the edges. In addition, the material is organic, based from epoxy provide enough elongation to absorb impact and flex with movement in order to prevent pop-outs.

The Epoxytec 17G was a well-thought solution. It was specifically formulated to combat the wearing forces of the solid waste transfer station push-walls. In addition, because of the degree of concrete loss - the Epoxytec 17G rebuilds as a sealed epoxy slab with 17,800psi of compressive strength to reinforce structurally, and cure with such high density that it truly becomes a brute system to combat the abuses the push-walls experience.

Wood forms had to be lined with plastic as a release agent. Typical release agents and molding waxes would not suffice. Epoxytec 17G's adhesive strength to so extreme that it bond through most tradition release agents. This is a testament to its bond strength and surface tolerance/forgiveness.

A great attribute about the 17G is its pot life; with approximately 2 hours of pot life (working time) the job can go at a good pace without the worries of losing a kit after mixing from exotherm (ie - overheating with a quick cure).

The Epoxytec 17G was selected because it's epoxy-based; and therefore, once cured provides a protective sealed barrier and disallows oxygen and other contaminates to migrate through concrete. Sealing the concrete and disallowing oxygen to the rebar will cease oxidation from further occurring and protect the bars for the future.

After removing the forms, the resulting system is Epoxytec 17G as a repair system, rebuilder, filler, and also a high impact, durable, abrasion and chemical resistant sealed liner.

Using a material like 17G results in the ability of feather-edge bonding without the harm of popping or weakening at the edge.

Concrete, or inorganic material, with near zero elongation and mediocre bond strength will not perform well with feather edges or tapering. The simple lack of flexibility is a problem when impacted or if vibration occurs - coupled with pour bond strength makes the prospect of using concrete to fix concrete a bad option. However, the optimal organic elongation and strong bond strength epoxy slab-type materials, such as the 17G, bridges these concerns and provides a solution to repair concrete and tamper it out to the edges for patching areas.

The Epoxytec 17G material is formulated to tie back into itself indefinitely, never losing it's maximum recoat window. In addition, the material can be built thin to thick (up to 12 inches).

The ability of Epoxytec 17G to have performance even at the edge gives an Owner to ability to budget for a full system rehab or sectional rehab in areas or patches.

The Epoxytec 17G is a DIY product. The material simply requires preparing utilizing uncomplicated water blasting. Once mixed, the material can be applied with minimal mobilization of human resources and equipment. In fact, the product is often installed with a simple mixing drill, trowel, forms (if vertical), and has a 2-hour pot life. With no solvents or VOCs, an application crew can apply with peace of mind.

Unlike utilizing cemetitious mortars, which typically have somewhere between 7 - 28 days to reach full compressive strength, and require extreme undercutting to repair. Epoxytec 17G reaches extreme compressive strength quickly, and requires less preparation and logistics to apply. From an operational standpoint, using this system saved the Owner from downtime which converts to cost svaings. Returning the push-wall back into service at a fraction of the speed of concrete makes the 17G an attractive candidate for uptimal operational production considerations.

Once completed, the Epoxytec 17G brought the push-wall back to service with enhanced 17,800psi compressive strength, and with sealed and protective lining capabilities. An upgraded performance system will now shield against corrosives, abrasion and high scoring impact.

Returning the push-wall back to service in rapid time (versus slow curing cementitious alternatives) translates to operational productivity. With a more durable push-wall than previous, reducing the rate of future shutdowns and repairs adds furthermore to cost reductions going forward and exponentially compounds savings indefinitely. Epoxytec's ultimate goal is to deliver life extensions to infrastructure, and utilizing products like 17G makes these objectives realized across many industries.

Wooden Drinking Water Tank, Mount Sinai Medical Center (Miami Beach, FL, USA) - rehab and monolithic immersion lining

2009-08-08T16:08:00.052-04:00

Mount Sinai Medical Center & Miami Heart Institute - Miami Beach, FL, USA Potable Water Storage Tank, wood rehabilitation and monolithic lining
October 2005
Epoxytec certified contractors: Engineered Lining Systems

Mount Sinai Medical Center, a historic hospital in South Florida (coastal Miami Beach), sought Engineered Lining Systems and Epoxytec to solve a logistical and rehabilitative challenge. On top of the roof, an old custom built wooden tank has been leaking into a catch containment recirculating draining system. This system came with constant headaches, making tenants nervous because of the frequent overflows and leaks coming through the roof, ultimately through ceilings and into the hospital corridors and rooms.

Unfortunately, access to this area is extremely hindering, and the idea of rebuilding a newer designed tank because of these access limitations and coupled with restrictive budgets makes it nearly impossible. However, a restoring solution was recommended by the Epoxytec team. And when installed successfully, the proposed high build elastomeric liner will last and endure as good as . . . if not, better than replacement, within budget, and without hardly any interruption.

As seen above, this tank was built entirely with wood, and because of all the seams, constant leaking is an everyday consequence. Once the water is removed, the wood will lose its swelling state, and in fact, the seams will open even more as a result.

To combat this, extra steel bands were installed and will be tightened while the wood dries.

Epoxytec proposes an extremely elastomeric (flexible) material to use as a liner. Elastomers do provide elongation greater than most liners can provide; however, often times the materials used for elastomerics, such as polyurethanes or polyurea, can be a bit sensitive to the substrate if not prepared correctly.

For this project, the wood and area needed to be dehumidified, using industrial blowers to evaporate all moisture from the area and within the matrix of the wood.

In addition, the wood needed to be sanded down in order to achieve a good profile and a clean, grainy wood surface.

When completed, a test area was evaluated, and the total bond strength was enough to peel off the actual wood itself at around 400 psi. This resulting adhesive performance was acceptable to continue.

As a fail safe, and for extra measures - Epoxytec suggested introducing a water-borne epoxy primer before coating with the elastomeric liner.

The Epoxytec B2 Primer is great for this kind of application. Because it's water-based, any remaining moisture in the wood will not affect the primer; since it is made from water, it will integrate with any remaining or foreseen moisture in the wood.

Another advantage in this situation is the recoat window. Recoat windows (the time you have to coat on top of a previous coating) when using urethanes (such as the liner utilized for this project) is very important. If an applicator were to coat to prematurely before the primer was ready, the system could experience a total failure and delamination as the primer would have been too wet. On the contrary, if the primer dries too long, it would create a slick and sealed surface, hurting the bond strength of the topcoat urethane liner (missing the recoat window).

The Epoxytec B2 Primer is color-indicating. It's goes on grey, and when it turns clear - it's ready for top coating. This takes out all the guessing, and gives the applicator a true "green light" for spraying the top coat.

When the B2 Primer cures, it will seal out all remaining moisture, providing a totally dry and active ionic exchanging substrate for bonding any top-coating. Typically, another 100 - 300 psi can be added to the total adhesive strength of the top coat when using primer.

Water-borne epoxy primer - Epoxytec B2 Primer - going on grey, and ready for top-coating when it turns clear.

Epoxytec certified applicator is preparing a mix of material to be used for filling all major gaps and seams of the wood.

The mixed wood sealant and filler, is a two-component polyurethane joint sealant - Epoxytec Uroseal 45V. This version of Uroseal stays in a thixotropic gel state for vertical and overhead applications. This urethane thixotrope will provide the contractor the ability to use a spatula or putty knife to simply fill all major seams between the wood boards before coating.

Using a plastic spatula - the 100% solid urethane joint sealant is applied vertically.

Epoxytec Uroseal 45V is an elastomeric filler, and will be a totally compatible system underneath the top coat liner (both polyurethane, elastomeric in nature with similar elongation properties).

Suiting up for the final coat. The application will be applied by spray; therefore, taking proper precautions to avoid the harmful atomized mist and over-spray is required. The use of tyvek suits, protective gloves, head and face protection with forced air is typical.

The liner material will require the use of a plural component spray equipment. This dual component spray gun and rig is typically used when applying rapid cure, high build coatings such as polyureas and quick cure polyurethanes.

The material being sprayed is manufactured by Epoxytec. For an ultra-high build, ultra-elastomeric, seamless/monolithic lining system, as required for this wooden tank project and as required for potable drinking water (conforming to ANSI/NSF-61 standards), Epoxytec recommended its Epoxytec Quick Blue lining system.

Epoxytec Quick Blue has to be sprayed in plural component methods due to its ultra-rapid curing properties. The Quick Blue lining system immediately begins curing in 30 seconds. This allows the material to build on top of itself, as thick as desired. In addition, this also gives the project a speedy return-to-service (delivery). This lining scope of the project was completed in 4 days, and water was returned to the tank in less than a business week.

The ultra-high build, elastomeric qualities of the coating provides the benefit of filling small crevasses, gaps, and seams as the applicator sprays. Keeping the nozzle spraying in the seams provides a "fill-as-you-spray" option to the contractor.

The rapid curing benefits of the material will give the applicator ample time to spray sections of the floor, and soon after walk on top of it within a few minutes.

Considering the material is extremely flexible (300% plus elongation), the spray liner material (Epoxytec Quick Blue) is used to fill and line at the same time. The contractor is slowly spraying all joints of the intersection between the floor and walls, and also filling all gaps surrounding the anchors of the ladder. Spraying slowly with a rapid cure material gives the applicator the ability to build up to any thickness required.

Considering the tank is approximately 20 feet in depth; crew supervisors at the top keep a close eye on the spray application crew below. Following strict confined area entry procedures gives confidence to the applicators below.

Epoxytec Quick Blue provides a long-lasting, chemical resistant, monolithically sealed system. This system will hold all water for storage without any more leaks or compromises.

When completed, and fully cured - the Epoxytec Quick Blue system seals with a rubber-like texture. This cold applied, two-component spray coating is similar to having a thick rubberized liner inside the wooden tank. The material system provided incredible cost savings, preventing replacement with limited downtime and resources.

The final liner was applied at around 125 - 250 mils (1/8" - 1/4"), and in some areas (such as in the seams and joints) up to 500 mils (1/2") dry film thickness (DFT).

Secondary Containment, Allied Universal Chemical (Miami, FL, USA) - concrete epoxy repair

2009-08-07T17:28:00.018-04:00

Allied Universal Chemical - Miami, FL, USA
Epoxy paste, for concrete repair in chemical secondary containment tank
August 5th, 2009

Epoxytec was requested by Allied Universal Chemical, a chemical distributor and manufacturer of specialty chemical and hydrocarbon blends, to repair a section of concrete spalls and cracks.

Epoxytec needed to recommend a material with high surface tolerance, being that abrasive blasting could not be utilized for this section.

The spall presented a challenge - it was deep, under-prepared, and exposed to concentrate chemicals.

[PLAY VIDEO]
for more videos, visit Epoxytec TV

Epoxytec CPP was utilized for it's high level of compressive strength and density (16,000psi), it's ultra-forgiveness to questionable surfaces, and it's 100% solid epoxy durability and resistance.

The CPP, once applied and cured seals and protects the substrate. This was applied in one pass at about 1/2" thickness tapering out to around 1/16" on the edges.

Manhole Rehabilitation, Rockdale County Water Resources (Rockdale County, GA, USA) - Epoxytec DIY Program training

2009-08-04T15:27:00.073-04:00

Rockdale County Water Resources - Rockdale County, GA, USA
Trowel-applied, Structural Epoxy for use in manhole rehabilitation
July 2009
Epoxytec DIY Program - municipal

In July of 2009, Rockdale County, GA contacted Epoxytec for help in dealing with water infiltration in their aging manhole infrastructure. Rockdale County is situated just South of Atlanta, GA. Epoxytec recommended the use of our 100% solid, cold trowelable epoxy - Epoxytec CPP.

Epoxytec mobilized a team to Rockdale County in order to train their in-house crews. This was done to ensure that they fully understood Epoxytec CPP and how to best utilize it. The CPP will be effective for stopping future infiltration, and also adding long term protection against Hydrogen Sulfide (H2S) and other corrosive by-products.

As is customary with Epoxytec's thorough training procedure, the first part of the training session was held at the maintenance yard before heading out to the field.

[PLAY VIDEO]
for more videos, visit Epoxytec TV

Video showing parts of training demonstration.

After the initial training and product orientation, Epoxytec followed the crew out to the field to begin work on a troublesome manhole which had displayed some water infiltration.

Rockdale's crew on-site with Epoxytec.

The leak is visible right above the channel.

After all the active leaks had been stopped, the surface was prepped using high pressure water blasting. As long as the concrete is sound, Epoxytec typically recommends a minimum of 5,000psi water blasting for application of Epoxytec CPP.

The necessary confined space safety gear was put in place and the application was started.

The Rockdale crew did a great job on their first application of Epoxytec CPP. Their professionalism and work ethic was impressive. This is a true testament to the high calibre supervision and leadership of these crews.

A typical eight foot manhole lined with Epoxytec CPP. 1/16" DFT.
(Photo taken in Nipomo, CA 2009)

Fire Station, Concrete Floor Coating - Miami-Dade Fire Rescue (Westchester, Florida, USA)

2009-07-09T20:20:00.033-04:00

Miami-Dade Fire Rescue - Westchester, Florida, USA
Westchester Fire Rescue Station
High Performance, Non-Skid Architectural Epoxy Floor System
January 2008
(performed by an Epoxytec certified applicator)

Westchester is a community within Miami-Dade County, Florida. The County's Fire & Rescue Department has dozens of stations both old and new. Epoxytec was selected by Miami-Dade Water & Sewer to recommend non-skid epoxy floor renewal systems for concrete protection against wear, chemicals, and other corrosives and abuses. In addition, the epoxy floor needs to be durable, long lasting and provide sealed lining.

The floor exhibited a asphalt-modified-type coating previously installed which require abrasive blasting to remove.

After sand blasting, the floor was washed and decontaminated.

The floor was further prepared by sealing and repairing all surface cracks with epoxy - Epoxytec CPP Gel.

After completing all surface preparation in accordance to NACE No.6/SSPC SP-13, the first coat of resin was applied - Epoxytec CRM Modified.

The CRM Modified is a clear epoxy resin formulated for thick floating capabilities in order to introduce granules for non-skid flooring. The material is chemical resistant and can be rolled between 15 - 20 mils per coat.

Before losing the window for granular embedment, the Color Quartz Granules have to be broadcasted before the resin cure too much to prevent granules from soaking into the resin. Therefore, timing is essential and applying resin with granules often times require application in sections on large surface areas.

First coat of nonskid with granules completed at 20 mils DFT.

After blowing off excess granules, the 2nd coat is performed.

Two full non-skid coats cured and completed at a total of 40 - 50 mils DFT.

Flat Roof, White Elastomeric Coating - The Trump Group (Miami Beach, Florida, USA)

2009-06-16T22:36:00.017-04:00

The Trump Group - Miami Beach, Florida, USA
404 Washington (South Beach)
White Elastomeric Roof Coating
Ponding Water Resistance and Sealing
January 18, 2008

When Taylor & Mathis consulted Epoxytec in search of a simple-to-apply, DIY type roof coating we knew they came to the right place. One characteristic that distinguishes Epoxytec from the competitors is that Epoxytec does in fact manufacturer a line for Do-It-Yourselfers, termed the DIY Program.

The building located at 404 Washington (owned by The Trump Group) is located in Southern Florida, and is a landmark at the famous beach strip on Miami Beach locals call - South Beach.

This fact is important in order to describe the environmental impact on the roof. South Florida is known for high humidity, rain, heat and being by the beach salt fog. Most coatings cannot cope with these challenges, yet alone perform well and be applied by Do-It-Yourselfers.

The roof system called for a white coating to reduce the absorbtion of heat and increase AC efficiency, an important benefit most South Floridians specify.

In addition, the coating system needed to be specific to roofing - it needed to bond and tie into a previously installed bitumen modified system, be elastomeric, and be a monolithic sealed system that will protect the roof, seal from infiltration, and tolerate ponding water.

Being applied in-house, the material also need to be safe, surface and moisture tolerant, and easy-to-use (applied by roller or squeegee).

The recommended and applied system was Epoxytec Elastoroof PW.

Being elastomeric, the use of reinforcement tape is an added reassuring system that can be incorporated with the Elastoroof coating for joint sealing reinforcement.

The white elastomeric roof coating can be applied by roller at the convenience of the crew, in sections or in its entirety.

Applying the Elastoroof PW coating throughout the entire surface, including over the reinforcement taped joints.

The roof coating system is applied monolithically in two coats for total dry film thickness of circa 20 mils.

Parking Garage, Concrete Repairs, Floor & Beam - Plaza Las Americas (San Juan, Puerto Rico)

2009-06-16T22:08:00.018-04:00

Plaza Las Americas - San Juan, Puerto Rico
Mall Parking Garage
Concrete Repairs, Elastomeric Urethane Crack Repair & Leveling Epoxy
September 2005
(performed by an Epoxytec certified applicator)

Concrete repair work was in order at the Plaza Las Americas mall in San Juan, Puerto Rico. The high traffic areas were being worn down due to vibration and constant auto traffic. Previous cement-based repairs were temporary, feather edging and tying into existing concrete proved problematic, and when excessive vibration, expansion or contraction occurred, the concrete-based repair simply popped. An epoxy-based repair for the floor and an elastomer crack sealant was the right solution for this project.

Concrete floors undergo constant vibration, movement, expansion/contraction. Concrete, cement-based mortars would not hold up, could not absorb vibration, nor could be thin-feathered to the edge and therefore failed and popped.

A solution provided by Epoxytec was the Epoxytec 17G. Using Epoxytec 17G gave an organic-based material with elongation, ultra-high bond strength, feathering/thinning capability, 17,800 psi compressive strength, and a sealed and protective repair to protect rebar and underlying concrete.

Below is a picture of a concrete repair in the same parking garage. The crack was at the joint, and undercut was made to allow a good anchoring profile for an elastomer to be utilized. Epoxytec Uroseal 45V is a 2-component, 100% urethane joint sealant, made for ultra-high elongation and flexibility. In addition, the material is protective and sealed.

Motorcycle Trailer, Non-skid Epoxy, Wood Floor - XTR Speed (Fort Lauderdale, FL, USA)

2009-06-16T08:57:00.018-04:00

XTR Speed - Fort Lauderdale, Florida, USA
Wood Motorcycle Trailer
High Performance, Architectural Non-Skid Epoxy Floor
February 20, 2004
(performed by an Epoxytec certified applicator)

The owner of XTR Speed sought a solution from Epoxytec in order to provide a durable, high performance coating for race bike storage, servicing, and showcasing. The floor that needed to be addressed was wood, and required a coating that could incorporate non-skid granules, yet be topcoated for easy cleaning. On a technical note, Epoxytec required a coating system that was chemical resistant, sealed the wood, and had good elongation as flexibility during with road traffic, driving, and hinge opening/closing could present a challenge.

The coating system selected was CRM Modified; exhibiting great elongation, performance, and durability.

The CRM Modified system is a clear high build epoxy, used with granules (in this case, black and blue) provided an ideal solution to the challenges a moving trailer presented and the durability requirements of holding up to chemical and hot tires.

Close-up of granules - 3M Color Quartz.

The swing door is hinged and required the Epoxytec CRM Modified to bridge abuse and vibration.

Top coating with the Epoxytec SLF (in clear) provided an attractive high gloss finish and an easier surface to clean, yet thin enough to expose coated granule peak for continued non-skid, anti-slip.

3 Coat system: 1 coat of Epoxytec primer @ 5 mils, 1 coat of Epoxytec CRM Modified (with mixed granules) @ 18 - 20 mils, 1 top coat of Epoxytec SLF (clear) @ 12 - 15 mils. Total DFT = 35 - 40 mils.

Condominium Service Level Floor, Concrete Architectural Non-skid Epoxy Floor - L'Hermitage (Fort Lauderdale, FL - USA)

2009-06-13T19:09:00.038-04:00

L'Hermitage II - Fort Lauderdale, Florida, USA
Lower Level Condominium Service Halls, Loading Docks, Garbage Shoot Floors
High Performance, Architectural Non-Skid Quartz Granule Epoxy Floor System
February 2, 2004
(performed by an Epoxytec certified applicator)

The lower levels of L'Hermitage Condominium required an epoxy system to protect the concrete against corrosives such as detergents, loading dock and receiving wear, garbage disposal and servicing, etc. However, the area was also the lower level entrance from the parking garage where tenants would walk the halls to the elevators. The Board of the association requested a safety coating, a non-slip so that normal foot traffic would not be prone to slip with a high coefficient of friction compliant to ADA requirements as specified by NACE/SSPC.

After addressing cracks with Epoxytec CPP, a concrete epoxy filler, the total surface was blasted via shot blasting in order to profile the surface while reducing dust.

After all surface preparation was completed, the first coating applied was a primer designed to prevent moisture vapor transmission (MVT) as a precaution. Epoxytec B2 Primer, is a water based epoxy primer always recommended on floors to help with any MVT, reduce off-gassing, and prevent pinholing on subsequent coats, and improve bond strength.

The 1st coat of epoxy was applied. Epoxytec CRM Modified is a popular selection when working with color quartz granules for anti-slip. The coating is clear and thick, allowing for a prefect formulation to embed granules into the coating. The color can be customized to any variation as the color comes strictly from the mixing of course color media not the epoxy.

While the Epoxytec CRM Modified is still wet, the granules are broadcasted on the coating - moving from section to section.

The excess granules are removed the following day by blower, vacuum, or sweeping. After which, the process is repeated again - two coats, at about 25 mils each for a total of 50 mils each granular coat.

Once the two granular coats are completed, an optional top coat was requested for added gloss, and better mopping and cleaning capability.

Considering the application is indoor (and therefore, U.V. was not a concern), the top coat was applied with the same epoxy - the Epoxytec CRM Modified.

With the final top coat - the total system applied was 4 coat steps (1 prime coat, 2 granular coats, 1 top coat) for a total of 60 - 75 mils DFT.

After the hallways were completed, the applicator then proceeded to the loading dock areas. The coating is durable enough to combat the wear and abuse of loading dock area operations, resist the refuse chemicals and contaminants, and can be pressured cleaned with detergents without adversely effecting the coating.

Warehouse Floor, Protective Epoxy Floor Coating - Dallas 1 Corporation (Thonotosassa, FL - USA) - concrete epoxy-urethane floor coating

2009-06-07T10:22:00.023-04:00

Dallas 1 Corporation - Thonotosassa, Florida, USA
Warehouse Garage Epoxy Flooring (High Gloss)
September 2006

The smooth concrete surface profile required abrasive blasting and surface preparation according to SSPC SP-13/NACE No.6 "Surface Preparation of Concrete."

After proper prep, Epoxytec's certified contractor utilized a water-borne epoxy primer called Epoxytec B2 Primer. The primer is ideal for floors; being water based, moisture does not hinder its ability to penetrate and cure properly (in fact, it helps with absorption). In addition, the deep penetration and saturation allows for a cured, and sealed barrier against the annoying forces of out-gassing, hydrostatic pressure, and moisture vapor transmission. These advantages are very beneficial, and in addition, the primer provides better bond strength without compromising the blasted profile.

Primer detailing by brush.

The Epoxytec B2 Primer is color-indicating. When the primer turns to clear, the top coat is ready to be applied. For a durable, high gloss, protective and easy-to-apply solution - the Epoxytec SLF was selected as a top coat epoxy floor coating. The SLF is a 100% solid, urethane-modified-epoxy (UME).

1st coat of Epoxytec SLF is being applied at 10 - 15 mils dry-film-thickness (DFT).

The SLF top coat material is simply to use, simply roll, squeegee, or spray. For this project, rollers were selected.

Completing the 1st coat and moving onto the 2nd coat of 10 - 15 mils. The total DFT is being targeted at 20 - 30 mils.

The completed project took place in 2006. The material will perform and provides maintainability, as recoating or touch-ups can be performed indefinitely as the recoat window stays open and requires no major prep - just simply clean and reapply if needed.

Warehouse Shop Floor, High Performance Epoxy Floor Coating - Dallas 1 Corporation (Thonotosassa, FL - USA) - concrete protective floor coating

2009-06-06T15:11:00.014-04:00

Dallas 1 Corporation - Thonotosassa, Florida, USA
Warehouse High Performance Epoxy Flooring (High Gloss)
August 2006

Utilizing abrasive blasting to achieve proper surface preparation to SSPC-SP 13/NACE No. 6, "Surface Preparation of Concrete," Epoxytec certified applicator - Dallas 1 Rehabilitation Solutions proceeded to prime the warehouse concrete floor.

(prepared and priming with Epoxytec B2 Primer, water-based epoxy primer)

Two coats of urethane-modified-epoxy coating, Epoxytec SLF was applied by roller @ 30 mils DFT. The coating is protective against chemicals, seals, protects and self-levels to an ultra-high gloss epoxy finish.

After final coating is applied, the drain coverings are removed, inspected and touched-up in order to achieve a monolithic coating system.

Drains are touched up - project is completed.

City of Plant City’s Tax Dollars Spent Wisely

2009-04-21T09:21:00.014-04:00

Rehab with in-house personnel saves money
“Do-It-Yourself” In-house Rehabilitation
by Dr. Elena Ubals

Today’s economy has proven to be challenging for many. Revenues are limited and budgets are restrictive; however, many municipalities still have to confront the real troubles of infrastructure rehabilitation. Let’s face it, although revenues slow down, corrosion does not. Many municipalities are adjusting their capabilities to proactively address corrosion during budget restraints in order to stay ahead of the high cost of replacement.

Municipalities of all sizes often times utilize in-house personnel to respond to infrastructure emergencies or oversee the similar operations. Some municipalities diversify the capacities of their in-house crews in order to efficiently produce a wide range of functions, which at times can include repair of manholes, pump stations, plant structures, and other key infrastructure. Having a diversely skilled crew not only creates and retains local employment, but also stretches municipal budgets.

When the City of Plant City, Florida realized that for simply resurfacing and protecting manholes, doing so in-house could stretch their budget, they were drawn to the idea of launching a committed in-house manhole rehabilitation program. “A contractor could take care of everything, but we were already in the field inspecting and grouting leaks and wanted to look into lining our manholes as well,” says Wayman Kingsley, Inflow & Infiltration Supervisor. “My job would be easier with a contractor, but with the same budget, we thought we could get many more manholes completed just doing it ourselves.” “We still need contractors for more cumbersome projects involving pumps, replacement, etc; but when it’s just resurfacing and coating, we can do it ourselves.” Kingsley adds, “It was important to take the project at our own pace, and we weren’t looking to complicate the mission with bids, conflicting contractor time schedules, engineering expenses – those costs could add pretty fast.”

Wayman Kingsley’s point is well noted. Delays in inspecting structures, engineering a system to address them, make a public announcement, manage the award and possible protests, oversee the contractor in the field, and wait for the installation to take place, could prove timely and may be interruptive to the daily City priorities which constantly change. Bid processes could take weeks, months, or years and meanwhile, the structures continue to deteriorate and worsen. However, if local governments streamlined a Do-It-Yourself (DIY) approach, trained employees could mobilize at their convenience and utilized stocked material to rehab a structure themselves in a matter of hours, rather than in months or years.

Plant City has successfully built a small in-house rehabilitation program over the last few years gaining knowledge about their installations and stretching the tax dollar to get more done with the same budget than if contracted out. Kingsley adds, “The DIY method gives us more control of our time, lowers cost incurred by 3rd party vendors, and creates a skill and greater understanding of what’s in our systems and how we can deal with it for the long haul.”

In-House Protective Coatings
The long-term cost savings of preventive maintenance and trenchless rehab methods are well-known. The right protective system with the correct installation techniques extends the maintenance cycles of vulnerable concrete and steel wastewater infrastructure, especially when exposed to hydrogen sulfide. Avoiding replacement costs by protecting and sealing manholes with sewer grade protective coatings was a plan that Plant City decided to implement as an addition to their field maintenance program. Wayman Kingsley utilizes a coating system that is specifically designed for DIY-type municipal crews, “We tested four different coating systems, and although performance was imperative, an equally important criterion was to find a system that that could be easy applied and fit our capabilities.” “We needed a product that was safe with no solvents or fumes, it had to have great bondability and tolerance to the surface and moisture, it had to have superior chemical resistance to H2S, yet at that same time, it needed to be applied easily with simple mobility, and not require heavy or complicated equipment.”

Kingsley further states, “For manhole environments and simplicity, we found that Epoxytec Uroflex and CPP were best suited for Doing-It-Yourself. Epoxytec provided all the training necessary to get us up and running. We are able to apply the materials often times with just a roller or trowel. Sometimes we use the Epoxytec EZ-Spray system which is just simply a small cartridge gun that is fully disposable and self-mixing. Some of our manholes just require 6 – 8 cartridges to line the entire thing, which equals to $330 - $440 worth of material that is designed to seal and protect the manhole for many years.”

Mike Caputi, spokesperson for Epoxytec states, “We have developed a product line with all size municipalities in mind who want to undertake some rehab projects in-house – this is our specialty.” “We wanted to create products that are forgiving, safe with no VOCs, and simple to use.”

Launching an in-house rehabilitative program is not always required, nor is it for every municipality. Sometimes, a rehab program could be limited or modified, where a contractor is used for a portion or a more difficult part of the project (for example - rebuilding a manhole bench, resetting a seal, or chemical grouting, etc) and then the municipality may follow-up with simply coating themselves afterwards to save cost.

Wastewater infrastructure rehabilitation is so dynamic at times, but for simple resurfacing and coating one viable alternative is a DIY program. Many municipalities like the City of Plant City are realizing that tax money and budgets can be stretched, and once the “know-how” is in place, the DIY approach adds another solution for maintenance crews and budget cutting.

How to Start a Do-It-Yourself (DIY) Program for Manhole Rehabilitation:

· Determine if your human resources are sufficient to mobilize into a project.

· What are your expectations, capabilities, and at what rate do you want to achieve your goals?

· Consult with a product manufacturer that specializes in training and provides the proper know-how to meet your goals.

· Identify the structure, get trained and use the simple products designed for in-house projects.

Protective coating projects can be a great way to initiate or ‘test-out’ a Do-It-Yourself program.

Warehouse Floor, High Gloss Epoxy Floor Coating - APPI (Opa-Locka, FL) - concrete protective floor coating

2009-03-02T15:54:00.019-05:00

APPI - Opa-Locka, Florida, USA
Warehouse Epoxy Flooring (High Gloss with Color Flakes)
January 3, 2008

APPI of Opa-Locka, Florida is a manufacturer of specialty metal components. Due to the nature of their business, the concrete floors are susceptible to wear and impact often associated with warehouse and machine shop floors, but also vulnerable to corrosive attack from chemicals used in the production and treatment line.

APPI needed to a floor coating to aesthetically restore and beautify the floor being that many clients visit the operation, while at the same time, the floor coating had to be high performance enough to resist abuse and properly seal and protect the concrete against corrosives.

APPI sought the advice and consultation of Epoxytec. Epoxytec was summoned to inspect the concrete floors at APPI and conduct a full service concrete coating inspection to help uncover the cause of previous coating failures. After prescribing remedial recommendations, Epoxytec was requested to specify a solution that will last and perform for decades.

After conducting an intensive concrete coating inspection, with a certified SSPC concrete coating inspector provided by Epoxytec; two main causes of failures in the past were discovered - high production of moisture vapor transmission (MVT) and a loss of primer recoat window or incompatible primer (adhesion to primer).

(top-coating over Epoxytec B2 Primer)

Considering the high level of moisture vapor transmission (MVT) and possible logistical errors of timing between priming and recoating made in past installations of coatings, Epoxytec recommended utilizing Epoxytec B2 Primer. The B2 Primer is a recoat color indicating, water born epoxy primer.

The advantages of having a color indicating primer will provide the applicator, in this case the in-house maintenance personnel (utilizing Epoxytec DIY support), with zero logistical timing errors. The applicator does not have to calculate nor time the recoat or topcoat window, instead, the applicator will simply be able to topcoat the primer when the color changes. As the color of the B2 Primer changes from grey to clear - it is ready for top coating!

The second advantage of using water-based epoxy primers, such as the B2 Primer, is its effectiveness in combating high levels of moisture or humidity, especially in concrete floors experiencing debilitating moisture vapor transmission. Most solvent based, or other solid resin based epoxy or urethane primers/coatings cannot effectively bond when moisture or vapor transmission is present in high concentration within concrete. They simple weaken the bond, prevent a good wetting anchor, and ultimately delamination occurs as the curing takes place or later in the service life.

For many typical epoxies, water equals hardship in bonding. However, being the the B2 Primer is made from water, there are no adverse effects to the primer coating during or after the application. In fact, any time Epoxytec suspects moisture may be a concern, leaning to the B2 Primer is protocol, and is recommended as a tool in all flooring contractor's tool box.

After the B2 Primer cures, an top coat must be applied within the 48 hour recoat window. APPI selected the Epoxytec SLF top coat. SLF is a urethane-modified-epoxy (UME) top coat system.

The Epoxytec SLF system is easy-to-use, 100% solid high gloss epoxy. With the urethane modification, it makes it also impact tolerant. The high gloss system is beautiful, yet resilient and durable, holding up to most chemical attack and wear. The system protects the concrete, yet remains practical and easy to clean.

The Epoxytec SLF coating is often sought for air craft hangers, industrial flooring, showrooms, and warehousing.

As you can observe in this picture, the coating is applied at a decent thickness per coat - circa 10 - 15 mils.

APPI for safety reason and preference, decided on the addition of color flakes. Broadcasted on top the final coat, while wet - tacky (before the product cures), provided an orange-peel finish, which increases the coefficient of friction making is ADA compliant to non-skid regulations.

Epoxytec in fact, not only recommends this system for the benefit of added grip, but also because it hides unintentional scuffs or disparities which often times cannot be avoided.

Wastewater Grit Channel - City of Klamath Falls - concrete rehabilitation & protective coating

2009-02-17T20:52:00.022-05:00

City of Klamath Falls, Oregon-USA
Grit Channel
January 21,2009

Examining the wastewater treatment plant grit channel at Klamath Falls, Oregon unveiled a deteriorating situation where abrasion and erosion, combined with hydrogen sulfide accelerates the original concrete's rate of corrosion.

To remedy the effects of corrosion, the City turned to Epoxytec for an outperforming material that is safe and easy to self-apply in order to restore and line the channel in a one-shot application. Approaching the project in-house, saved the City a consideration amount of money; doing so was possible with Epoxytec's DIY product line and support.

The material selected was Epoxytec 17G - a forgiving, tolerant, and simple to apply epoxy grout. Providing a solution to rebuild concrete and protectively line it in a one-shot application. The material is 100% solid with no solvents (zero VOCs). Exhibiting an ultra-dense 17,800 psi compressive strength, provides the channel a sealed and abrasion resistant epoxy-based slab. The material installation will rebuild and provide a long-lasting brute barrier to extend the maintenance life of the channel for years to come.

Epoxytec 17G being applied by trowel.

Epoxytec 17G provides a simply to maintain, easy to apply, and durable barrier epoxy slab. Great for all wastewater structures.

Bathroom Floor, Architectural Non-Skid Epoxy Floor Coating - St. Maurice Church (Hollywood, FL) - concrete protective floor coating

2009-02-06T19:49:00.011-05:00

Saint Maurice Church - Hollywood, Florida, USA
Restroom Epoxy Flooring, Non Skid / Anti Slip
(performed by an Epoxytec certified applicator)
February 4, 2004

The flooring project was part of a restroom restoration project. The concrete floor was bare (new slab pour, and fully cured), and water blasted before the epoxy flooring project proceeded.

To control off-gassing, the use of Epoxytec B2 Primer (water based epoxy primer) was selected prior to the coating application.

Non-Slip 3M Color Quartz Granules were broadcasted to embed the first coat of epoxy coating (Epoxytec CRM Modified).

Anti slip epoxy systems are often selected in bathroom areas as a safety feature to prevent falls by increasing the ADA recommended coefficient of friction and seal the concrete from corrosion and contamination.

The final top coat is applied to seal the valleys of the granules in order to make it easier to mop or clean. Sanitation is key when dealing with public restrooms, and top coating an epoxy traction system will seal the granules to assist with cleaning. However, using a thin coat is necessary in order to ensure that traction is still sufficient and that the coated aggregate granules still peak through the final top coat.

Miami-Dade Water & Sewer Stretches Tax Dollars

2009-01-31T19:00:00.017-05:00

A simple in-house project can be another cost saving tool in the tool box

In-House rehabilitation projects - “Do-It Yourself”
by Dr. Elena Ubals

In a challenging economy, where budgets are restrictive and revenues are stagnant or declining, many municipalities still face the real and potentially costly problem of infrastructure rehabilitation. After all, just because the economy is in a slowdown, corrosion is not. In this situation, some municipalities are choosing to adjust their capabilities to stay ahead of the corrosion curve and deal with corrosive issues to avoid the higher cost of replacement.

In fact, many municipalities have adopted the strategy of maintaining in-house crews for responding to infrastructure emergencies and performing general maintenance. Often, these service crews perform a wide range of functions, including the rehab of manholes, pump stations, wet- wells, plant structures, and other key infrastructures. It is an approach that not only retains local employment, but also stretches tax dollars.

That is what compelled Miami-Dade Water & Sewer (MDWS) to consider the “Do-It Yourself” (DIY) approach. "It would be nice to have a contractor take care of everything," says Rod Lovett, Chief of the MDWS Sewerage Collection Division. "It would make my job a lot easier. However, with bids, contractor fees, engineering and specs to consider, the costs add up quickly. Then there’s the waiting, which sometimes runs beyond the rehab window."

Rod Lovett makes a crucial point. By the time the structure is inspected, inspection results are reported, the project is engineered, publicly announced, awarded, supervised, and installed, too much time has passed. This allows the structure to deteriorate further, which may require replacement later. However, if local governments took the DIY route, trained employees could be in place with the necessary stocked materials; jobs that typically take months or years could be done readily in-house.

Miami-Dade County has built an in-house rehabilitation program over the last couple of decades. Lovett adds “The DIY approach eliminates crew downtimes and bid/award procedures, lowers costs typically associated with third-party vendors and promotes greater understanding of the products and installations."

In-House Protective Coating

The cost effectiveness of protective coatings is well established. The appropriate protective coating with the right preparation and application extends the service life of all substrates subjected to hydrogen sulfide. Furthermore, it is accepted that maintaining a coating system is much more economical than replacing structures.

In order to avoid replacement costs and further enhance the benefits of doing it yourself, Miami Dade decided to add protective coatings to their already existing manhole in-house program. In compliance with MDWS standards, Rod Lovett incorporated a protective coatings system for his manhole division. “At MDWS, we only use proven and tested products. Approved coating products must demonstrate moisture tolerance, bondability, and chemical resistance to hydrogen sulfide,” Lovett says, “We also look for products that are forgiving and have no VOC’s."

“There are many protective coatings approved by MDWS for different applications, but specifically for in-house manholes, we are using Epoxytec Uroflex and CPP. These products allow us to apply the coatings without complicated preparation or expensive equipment. We believe the in-house coatings program maximizes our rehabilitation capacity." Lovett says, “These products have proven themselves to be effective in our high hydrogen sulfide plant structures and manholes for many years."

Mike Caputi, spokesman for Epoxytec states, “We have developed products with the maintenance applicator in mind. Because our products are forgiving, adhesive, and easy to apply with no VOCs, they are specifically designed for the Do-It-Yourselfer, this is our specialty."

Clearly, there are larger and more complicated rehab and replacements jobs that should be outsourced through a qualified contractor, and of course, many projects are awarded to them. Sometimes though, it is cost effective to apply the protective coating in-house after the contractor has completed the more complicated portion of the work. In addition, by applying the coating in-house, the owner can select a higher quality coating and still save money.

Lovett says, “Here at MDWS we have over sixty thousands manholes, many of which are aging and in need of rehabilitation. After working closely with the inspection department, we then determine which manholes can be rehabed in-house and which ones need to be contracted out."

Of course, starting or expanding an in-house program is not for every municipality. The municipality must have the desire to build a program and enough rehabilitation demand to keep a crew active.

The Do-It-Yourself program can be a viable alternative to the bid/award process for some rehabilitation scenarios. Municipalities with tight budgets should at least consider starting an in-house program because, in the end, a simple in-house project can be another cost saving tool in the tool box.

Solid Waste Tipping Floor, Bay Floor #9 - Wheelabrator South Broward - concrete restoration and corrosion protection

2009-01-19T20:48:00.046-05:00

Wheelabrator South Broward - Hollywood, Florida, USA
Transfer Station / Tipping Floor Bay #9
(performed by an Epoxytec certfied applicator)
9/18/2008

Rehabilitative and protective solutions for the solid waste industry pertaining to corrosion induced by wear and chemical attack due to debris, scrap, refuse, and various solid and liquid waste.

It was with great pleasure to present solutions and services to Wheelabrator South Broward, a Waste Management company. Wheelabrator South Broward requested a solution from Epoxytec to address maintenance related rehabilitative and protective solutions in order to remedy current structural floor concerns in need of repair and apply preventive maintenance measures to combat corrosion and wear with superior materials as an alternative to current traditional methods in order to further extend the life expectancy of Wheelabrator's structures and assets, which in turn, will increase productivity.

In this case study, Wheelabrator S. Broward was experiencing ultra-high corrosion and loss of concrete at the tipping floor areas of their facility. Tipping floors at the Transfer Station are designed as an area where waste management garbage dump trucks empty municipal solid waste (MSW) into a refuse bunker for consolidation. MSW consists of a variety of unknown corrosives and abusive ruble. Within the matrix of the rubbish, various chemicals and organics are present. This is quite noticeable because of the intensely foul and putrid odors. Most facilities try to aerate the trash stacks, which unintentionally breeds further microbial induced corrosion.

Because the tipping floor is designed as a transfer station, the use of heavy equipment is essential. Bulldozer blades and other heavy mechanical machinery are constantly pushing the collected trash into piles and ultimately into the refuse bunker where it is collected. This method of brute and forceful transfer mechanics causes extreme wear, and the wearing effects are coupled with the abuses of heavy solid trash - mattresses, wood, boulders, heavy metal objects, etc.

An endless cycle of wear, impact, and abrasion, catalyzed with chemical corrosives results in weakened concrete and accelerated wear at an unprecedented rate. The tipping floor is the source of productivity for waste management processing plants, and loss of time due to slowdowns or temporary shutdowns are a large hindrance on Wheelabrator's operations. Finding a way to extend the maintenance cycle was imperative, Epoxytec was able to help.

Contracted ultra-high pressure (UHP) hydroblasting @ 40,000 psi performed by a specialized contractor.

Preparation was necessary to decontaminate and clean the concrete, rid the weakened surface, and expose the substrate for inspection and preparation before application of the new epoxy substrate solution proposed and developed by Epoxytec.

After blasting, the prepared surface revealed an incredible amount of concrete deterioration. The wearing effect of the tipping cycles, and trash transfer to the refuse bunker was so debilitating that original concrete reinforcing bars (rebar) was actually missing.

Epoxytec was called into Wheelabrator South Broward to customize a high performance, sealed and chemical resistant epoxy barrier slab with ultra-high density and compressive strength (17,700psi), and offer superior wear and abrasion resistance.

The caveat was that the material had to be forgiving to the surface and moisture levels always present at the waste collection tipping floor. The product needed to be tolerant to the endless impregnation of contaminants. The system ultimately needed to be simple enough to understand and safe to apply, easy to mobilize with uncomplicated tools and means if needed to be installed in-house. The material also had to have the ability to tie back into itself and be repairable for the future with rapid responsiveness and uncomplicated means of touching-up.

Upon examining the tipping floor bays, Epoxytec recommended utilizing a custom manufactured system designed just for tipping floor rehab - Epoxytec 17G (ultra-high density epoxy grout).

The Epoxytec 17G solution is a structural wear and abrasion resistant material, with an enhanced proprietary granule embedment and optional graphite blending to decrease the coefficient of friction and wear. The material is "green" and environmentally friendly, exhibiting a safe 100% solid formulation (no VOCs, no solvents, no fumes). Using the system provides Wheelabrator an ultra-high build material to combat wear with a quick return-to-service, thus extending the life-expectancy of the floor and improving downtime cycles to provide increased productivity.

The Type of Abrasion:

Unlike slurry troughs, high velocity pumps, or fine slit abrasion which is typical when trouble-shooting abrasion; Wheelabrator is rather experiencing a “sliding” friction-based abrasive condition with heavy abuse. Wheelabrator’s concrete floors are exposed to a cycle of impact, disposal on top of concrete and then a metal-to-concrete sliding force (also frictional abuse of other materials as well).

This “sliding” abrasive force was the focus of our study, which ultimately helped formulate Epoxytec’s recommendation utilizing 17G.

Fighting abrasion with abrasion-resistant fillers is great when combating a force with a stronger material filler than the opposing force (brute force results).

However, when dealing with sliding abrasion, a unique solution could present itself because of a different opposition – friction, thus a solution to facilitate the sliding effect is often sought. Creating slip (or a less coefficient of friction) ultimately slows down the rate of frictional abrasion or helps eliminate it altogether, hence, less friction/abrasion equals less wear.

High performance material manufacturers consider materials such as Teflon or Graphite to facilitate this process, however in this case - the constant and moist contamination delivered by the unloaded refuse provides enough slip, so a non-porous, sealed epoxy finish was sufficient.

To have solid strength, and also reduce friction (yet, not effecting the traction needed for machinery and vehicles) with a quick return-to-service and offering an easily maintainable system, Epoxytec recommended the development of 17G, a customized silica epoxy slab solution. The system also made economical sense (even with high build) without sacrificing any needed performance properties.

Other Considerations and Indirect Advantages:

Wheelabrator is also experiencing wear due to weakening concrete. As chemicals, water, solvents, and other fluid contaminants saturate the concrete floors, the surface of the mortar is compromised and weakened due to erosion, and chemical and microbial induced corrosion. The aforementioned can even effect higher density/psi concrete because of their vulnerable porosity (Epoxytec often realizes this fact in the wastewater industry as well).

When dozer blades and refuse slide across the surface, a small amount of soft (mush-state) and corroded concrete goes with it; the catalyst of weakening concrete is multiplied by constant daily cycles and contributes to the accelerated wear rate on concrete tipping floors. The original concrete has enough challenges to deal with regarding abrasion alone; if the concrete is in a constant state of weakening, then the concrete never stood a chance in a tipping floor environment.

The Epoxytec 17G system is not cementitious, nor porous. Rather, the system is a sealed, non-porous specialized epoxy-based solution. Unlike cementitious materials, Epoxytec 17G exhibits epoxy resin-based chemical resistance, and is immune to a saturated weakening surface effect. Using a sealed system that shields corrosive byproducts from the garbage piles also adds the benefit of protecting any remaining original sound concrete underneath the 17G epoxy barrier slab, further extending the structural life-expectancy of the area.

To prepare for the Epoxytec 17G application, it was recommended to first undercut a transitional edge so that the material would float flush with the original concrete areas not to be coated at the time. This way when the bulldozer blades are lowered and begin scraping, it would not hit a awkward impression or lip from the 17G installation.

Because Wheelabrator South Broward could not shut down the entire floor, Wheelabrator specified the installation of the Epoxytec 17G epoxy flooring system in sections. After completing the undercut transition edges, the material application could start.

Mixing the Epoxytec 17G.

An additional criterion Epoxytec considered during its recommendation, especially in Wheelabrator's case, was to improve maintenance cycles (while realizing the roll of maintenance is essential for longevity, but needs to be practical).

Epoxytec met the challenge by providing the ability for 17G to be easily repaired in a short amount of time, requiring simple tools and quick in-service down times.

In Epoxytec's opinion, the tipping floor area needs to be inspected on a cycle (which is a great practice for the long haul), perhaps every 12 months (more or less). Rather than recommending a system that requires complete shut-down and curing limits of days or weeks, Epoxytec 17G can be serviced or repaired in short time, cured quickly and returned back to service fast. Therefore, being realistic, if scores, dings, or other unforeseen abusive compromises took place that are isolated, rather than waiting until the end of the maintenance cycle to address it.

Epoxytec repair solutions involve simply identifying the area of concern and supplying a repair kit (requiring one or two men, with simple tools, i.e., spatula to pour and spread) to patch and tie the system back in. This practice prevents further large scale problems from potentially occurring and extends the service life of the entire system, while allowing normal production and preventing operational down-time.

One of Epoxytec's goals were to shift the maintenance cycle from the costly downtime of rebuilding concrete (slow process, long down time) to servicing the coating system with easy repairs that are fast, simple-to-apply, and quick curing for rapid turn-around and overall better performance. Doing this will be a key to a long-term successful and protective system.

Pouring Epoxytec 17G onto the prepared area. The system target thickness is one inch (1000 mils / 1").

The first section to be installed is directly before the refuse bunker. The section experiences the worst wear and is considered a priority repair area for the Epoxytec 17G to structurally restore, cure and protect.

Using the undercut method as describe previously, provided a flush transitional edge to minimize any impact.

Wastewater Clarifier - Miami-Dade Water & Sewer - concrete & steel protective coating

2009-01-11T20:47:00.029-05:00

Miami-Dade Water & Sewer - Homestead, Florida, USA
South District Wastewater Treatment Plant Clarifier
March 2003

Taking a "Do-It-Yourself" approach to save time and reduce cost was the goal maintenance crews at Miami-Dade Water and Sewer Authority (WASA) sought in order to solve their corrosive issues at South District's wastewater clarifier. Operations personnel decided to shutdown one of their wastewater clarifiers at the South District Sewer Treatment Plant in order for the maintenance specialists to apply a new protective topcoat to their steel and concrete surfaces in order to return the structure back into its next service cycle. Protection the steel and concrete with a premium coal tar epoxy coating will add years to the integrity of the walls, troughs, floors, and steel scrapers; and therefore the coating will extend the life of the structure and also extend the maintenance cycle as well.

After shutdown, immediately the steel started flash rusting due to a lack of any sufficient barrier protection from oxidation. The presence of rust is one indication, of many, that a coating was needed.

Miami-Dade's South District maintenance personnel selected using a Graco airless spray gun. Using a spray gun was optional, the coating selected could be rolled, however, because of the many intricate angles and bars that make up the steel sludge scrapers - it was best decided to spray rather than roll.

The Graco airless spray pump is shown here pumping Epoxytec UroShield Bitumastic, a proven coal tar bitumen-modified epoxy.

In-house maintenance crews begin spraying the steel clarifier sweepers using Epoxytec UroShield Bitumastic.

The steel sweeper structures get one coat of Epoxytec UroShield Bitumastic at 16 mils thickness.

The concrete walls and troughs get 2 coats of Epoxytec UroShield Bitumastic at 16 mils each for a total 32 mil system in order to properly fill the profile of concrete and add sufficient protection against algae build up and abrasion of the algae removal sweepers.

Miami-Dade Water and Sewer completes the coating project, and doing so all in-house, which saved the County considerable time and money. Doing the work in-house, with Epoxytec's support and training, also provided them the beneficial know-how and understanding of the systems protecting their infrastructure.

Wastewater Chlorine Contact Basin - Miami-Dade Water & Sewer - concrete rehabilitation & protective coating

2009-01-10T11:01:00.025-05:00

Miami-Dade Water & Sewer - Homestead, Florida, USA
South District Wastewater Treatment Plant
Chlorine Contact Basin
March 2003

Maintenance crews at Miami-Dade Water & Sewer shutdown a section of their chlorine contact disinfection system at South District Wastewater Treatment Plant for inspection. These tanks are typically coated with a coal tar epoxy coating and from the pictures, it was evident that the previous coating reached the end of its life cycle. The concrete surfaces have to be repaired and recoated to protect against the erosive activity of these troughs and from the corrosive nature of chlorination.

After high pressure water blasting, Epoxytec CPP was chosen to repair and fill any voids in the concrete before coating.

Epoxytec CPP is an epoxy paste used to fill, repair, patch and sometimes rebuild and line concrete. It is an ideal selection for this application because many of the voids are just shallow surface spalls and CPP can be applied ultra thin without any need for build-up, unlike mortar.

Note: if needed CPP can be built up to 1/2 inch per pass.

CPP structurally reinforces any damaged concrete with 16,000 psi compressive strength, has excellent bond strength and incredible tolerance and forgiveness to questionable surfaces (perfect for wastewater applications, as many unknowns often arise). Not to mention, CPP is chemical resistant and seals. It is easy to apply and has no harmful fumes - great for in-house, DIY municipal crews.

After patching the corroded area of concrete with Epoxytec CPP, crews began apply a roller-applied bitumen coal tar epoxy to stay consistent with prior and past material type selections. Because of the County's long history and success with Epoxytec, the material chosen is Epoxytec UroShield Bitumastic - a two component, modified coal tar epoxy.

One area of the basin (the back wall) was completely resurfaced with Epoxytec CPP.

Finishing up the rolling application of Epoxytec UroShield Bitumastic (2 x 15 mils for total DFT 30 mils).

Wastewater Lift Station #685 - Miami-Dade Water & Sewer - concrete rehabilitation & protective coating

2009-01-02T20:17:00.065-05:00

Miami-Dade Water & Sewer – Miami-Dade County, Florida, USA
Sewer Collections Division

Pump Station #685

February 2003

Pump station maintenance crews at Miami-Dade Water and Sewer decide to rehab and apply epoxy protective coatings to wastewater master lift station #685 in-house (DIY).

Inspection (pictures of concrete pump station surfaces, troughs and containment exposed to raw sewage, erosion, and hydrogen sulfide).

H2S corrosion taking a toll on the concrete walls, deteriorating the profile down to the rebar and potentially jeopardizing the integrity of the structure. Miami-Dade Water & Sewer crews got to the station in time to self-apply materials designed to structurally enhance the concrete, protect and seal it for its return to service and to further extend its next service life cycle.

Considering the surface showed major signs of contamination and rebar was exposed and oxidized/rusted. It was best decided to abrasively blast the concrete in lieu of high pressure water so that the steel rebar could be descaled while blasting.

Note: some lift stations can be simply high pressure water blasted, choosing between abrasive or water is simply a case-by-case judgement.

Initial blast passes reveals exposed aggregate, highly deteriorated surfaces with rebar exposure.

Miami-Dade Water & Sewer begins applying materials. They select Epoxytec products for the rehabilitation of the concrete and its protection with epoxy coatings. Epoxytec has been successfully training and supporting crews like Miami-Dade's in order to offer in-house, "Do-It-Yourself" municipal personnel the means to apply their own rehab and lining systems. Epoxytec is typically selected for DIY projects because their product line is environmentally friendly, "green" with no solvents nor V.O.C.s (volatile organic compounds). The materials are also very simple to apply, requiring everyday tools and minimal mobilization. Also, Epoxytec materials are proven to be very forgiving and tolerant to the surface, high levels of humidity, moisture, and other uncontrollable sewer contaminants that arise during application.

The incredible amount of concrete deterioration created the need to restore the concrete about 2 -3 inches (depending on different areas). For the resurfacing stage of the project, Miami-Dade crews selected an ultra-dense 10,000psi, quick curing mortar - Epoxytec MortarTec Silicate.

After applying the mortar, Miami-Dade then applied a very proven, durable epoxy as an intermediate coating - Epoxytec CPP. Epoxytec's CPP, has unbelievable bond strength, is chemical resistant and impermeable and therefore seals against infiltration (eliminating inflow), and refortifies the concrete with structural 16,000psi strength.

Epoxytec CPP works well for a simple in-house solution. The material requires minimal mobilization and tools, typically needing just a mixing drill and trowel. Also, the product is safe, 100% solid, no solvents (no VOCs). One other great feature, especially for trenchless, collection sewer systems is that it is extremely forgiving and tolerant to moisture and imperfect surfaces.

Lift station maintenance crews top coated the underlayment, consisting of Epoxytec Mortartec Silicate (rebuilding mortar) and Epoxytec CPP (epoxy liner) with a urethane-modified-epoxy (UME). Epoxytec Uroflex is a UME and proven with over 2,000,000 square feet coated at Miami-Dade Water & Sewer since 1989.

Considering the corrosion was so bad in this pumping station, the option to top coat with Uroflex will extend the life cycle with added H2S protection and grease build up prevention (the finish has great self-leveling properties and high gloss). Again, like the other materials, Epoxytec Uroflex is ideal for self-appliers being it is rollable, brushable, or spray optional. In this case, simple brushing and rolling was selected; therefore, requiring no need for complicated equipment.

Note: During this project, Uroflex came in seafoam green (used here as the first coat), and in red (used as the second coat).

Epoxytec Uroflex, 2nd coat in red.

The total system applied:

2 - 3 inches of Epoxytec MortarTec Silicate
60 mils of Epoxytec CPP
25 mils of Epoxytec Uroflex (1st coat)
25 mils of Epoxytec Uroflex (2nd coat)

Wastewater Final Settling Tanks - Miami-Dade Water & Sewer - concrete rehab and protection

2008-12-29T13:21:00.074-05:00

Miami-Dade Water & Sewer – Virginia Key, Florida, USA
Central District Sewer Treatment Plant
Final Settling Tanks (various)
2002 - 2003

Miami-Dade Water & Sewer shut down many of their final settling tanks at the Central District Wastewater Treatment Plant during the years of 2002 - 2003 for inspection and rehabilitation. When in-house rehab is necessary, the preferred method is to typically use repair and protective materials which are safe, tolerant & forgiving, and simple to apply. Often times this is where Epoxytec comes in. Epoxytec's DIY Program is an initiative Epoxytec created to help municipal crews tackle their own rehab and protective projects. Epoxytec does this with "green" product lines (no VOCs) and offers materials that are very simply applied by trowel, roller and brush (or optional spray) requiring no heavy equipment or complicated preparation. Epoxytec believes doing simple restoring and protective projects in-house saves a considerable amount of money, plus gives the maintenance crew a deeper understanding of the quality of materials going into their systems, what they are exactly and what they entail, and how to maintain the system going forward into the future.

The picture above is taken during inspection. The concrete appeared to have been coated, possibly during its original construction with what seems to be some type of coal-tar epoxy. The material manufacturer is unknown, and likely served its purpose beyond the time for which it was designed. The previous coating shows obvious signs that it reached the end of its life expectancy, and it's time for it to come off and have a newer protective coating system installed for the next phase of the settling tanks' life cycle.

The new coating will be what Miami-Dade Water & Sewer experiences their most success with - Epoxytec Uroflex. The Epoxytec Uroflex is also a newer generation, a more technologically advanced system than the older coal-tar type coatings. The Epoxytec Uroflex is a hybrid coating (urethane-modified-epoxy), offering the benefits of high performance epoxy, but modified with urethane to add more flexibility (important with concrete), closer cross-linking (less permeability), and higher gloss. These enhanced properties extend the life expectancy of the coating in some cases double or triple that of the generic 100% epoxy or coal-tar type materials.

After abrasive blasting, the surface was inspected again. Like mentioned above, although the previous coating reached the end of its performance life, it did serve its purpose and protected the concrete in a decent manner. The blasted surface does have some areas requiring patching and minor resurfacing repair; however, for the most part is suitable for direct coating by, in this case, roller.

The Epoxytec Uroflex will provide a tremendous benefit allowing the crew to roll the coating on most of the surface area without much need for trowel repairs. Even with some areas needing trowel work, most of the area will simply require rolling on Uroflex directly onto blasted concrete - from the beginning, this project showed signs of a very quick turnover and simple undertaking.

Miami-Dade Water & Sewer only needed two of Epoxytec's products to complete the rehab and protection of the final settling tanks' concrete surfaces.

The first material needed, being mixed as seen above is Epoxytec CPP. The CPP is one of the most popular DIY products that Epoxyec offers to resolve many different types of concrete restoration. CPP is an epoxy-paste that can be trowel applied to fill-in bugholes and deep crevasses, patch spalled areas, or even to rebuild/resurface and protect all-in-one-shot.

For this project, rather than using typical cementitious (cement-based) materials, Miami-Dade Water & Sewer utilized the Epoxytec CPP to 100% epoxy-reinforce (16,000 psi), seal and rebuild the troughs of the settling tanks. Not all the areas of the final settling tanks will require this level of reinforcement and protection; however the troughs experience a much higher rate of erosion than other areas, and therefore needed some minor resurfacing (1/16 - 1/8 inch) and using Epoxytec CPP reinforces and extends the life of these critical walls with an ultra-high performance system.

Note: although Epoxytec CPP leaves behind trowel marks as seen above. Please take notice in the next series of pictures demonstrates how nice you can finish the product by smoothing it down with water (much like a concrete, although it is 100% epoxy); this is a very unique feature for such a thick trowel-applied epoxy material (many other epoxies cannot touch water, yet alone use it to smooth it down).

Completed rehab of final settling tank troughs with Epoxytec CPP at around 1/16 - 1/8 inch. Providing a 16,000 psi reinforced, restored and smooth, sealed and protected premium revitalized surface. All this was done in-house, with a simple mixing drill and trowel, no solvents (no VOCs), no odor, and completed in under an hour.

After completing the necessary repairs, filling, patching and trough resurfacing, crews were ready to start applying the Epoxytec Uroflex coating. First coat was selected in red. the application will be simple, using a roller and applying 2 coats at 25 mils each for a total DFT of 50 mils.

The second coat of Epoxytec Uroflex is being applied in black. Using contrasting colors ensures successful coverage on the second coat.

The completed system of Epoxytec Uroflex is 50 mils total thickness. Among the many benefits Uroflex exhibits, such as flexibility, sealing capability, sewer guard performance, etc - having an epoxy modified with glossy urethane, provides the necessary protection against UV and algae build-up as well. The Epoxytec Uroflex system is a perfect selection for outside, open systems such as clarifiers and settling tanks.

Wastewater UNOX #3 & #4 (Closed O2 Anaerobic Digester) - Miami-Dade Water & Sewer - concrete rehab and protection

2008-12-24T16:29:00.065-05:00

Miami-Dade Water & Sewer – North Miami, Florida, USA
North District Sewer Treatment Plant
UNOX Tanks (various)

Epoxytec DIY Program - municipal
2002 - 2003

Epoxytec has supplied material and consultation to Miami-Dade Water & Sewer maintenance crews in order to perform "in-house" rehabilitation and protection of critical infrastructure. Doing this in-house, with Epoxytec's DIY Program saved the County considerable funds while at the same time allowing them the opportunity to select premium products and control the quality and pace of the project at their own convenience. Applying materials in-house also provides the crew a deeper understanding of exactly what was installed and how to maintain it for the long-haul.

Please note: 16 of the 18 Miami-Dade O2 Trains have been rehabilitated and/or protected with Epoxytec products; however the pictures in this report showcase UNOX trains #3 & #4 at Miami-Dade's North District Wastewater Treatment Plant.

Upon opening the hatch (agitator plates), considerable corrosion was observed and photographed. The worst corrosion appeared above the water line, where ultra-high hydrogen sulfide (H2S) was emitting sulfuric acid. The concentration of hydrogen sulfide is in a continuous state of progression considering these tanks are closed, with constant heat, oxygen is purposefully injected to activate sludge, then agitated. This creates the necessary microbial growth needed to breakdown solids, however, consequently also provides the perfect formula for breeding highly corrosive H2S.

In the picture above, you can witness the aggressive corrosive nature of H2S combined with the erosive forces of the agitators. These critical columns are missing a few inches of concrete and hence the rebar is totally exposed.

After abrasive blasting, the exposed aggregate concrete was inspected by Epoxytec for pH, spalls, bugholes (small cavities), active baffle wall leaks, overall cleanliness and contamination, and moisture levels before proceeding to repair and coating.

Epoxytec MortarTec Silicate (quick curing / circa 10,000 psi concrete) was selected to resurface and patch large spalled areas typically exceeding 1/4 inch in profile loss.

Epoxytec CPP (concrete polymer paste) was utilized for patching and filling areas less than 1/4 inch because of its thin application properties or for rebuilding critical areas due to its impermeable sealing properties, corrosion resistance, adhesion and 16,000 psi compressive strength.

The picture above highlights Epoxytec CPP for thin patching on the concrete walls and for ultra-high performance rebuilding of the critical columns.

Although the Epoxytec Uroflex coating system can be brushed or rolled. For this project, Miami-Dade Water & Sewer selected to airless spray the Uroflex coating.

Uroflex has been utilized on an estimated 2,000,000 square feet at Miami-Dade Water and Sewer, most of which has been applied in-house because of its ease of application (brush, roll, or spray), simplicity, "green" 100% solid (no VOCs) safety factor, and forgiveness.

Epoxytec checks the first few spray passes of the first coat of Uroflex (in seafoam green) for spray pattern and mileage thickness. After which, the first coat is applied throughout the entire UNOX train's concrete surfaces (walls and ceilings).

Selecting a light color of Epoxytec Uroflex for the first coat is beneficial for a few reasons. A light color lightens up the area and improves visibility (reducing the need for many lamps/lights). It also provides a good contrasting background for a darker second coat, thus allowing the applicator to be certain he or she is definitely covering the first coat.

In addition, using a lighter color gives the application crew an opportunity to visibly identify any unforeseen bugholes or repairs that went unnoticed. The nice thing about Uroflex is that subsequent patching or fillingwork can also be done in between coats; the recoat window is indefinite and using Epoxytec CPP to patch in between coats of Uroflex works well if something comes up during coating. Many other systems do not offer this incredible feature.

In the picture above, CPP is being applied thin to take care of an area that needed just a bit more resurfacing work because the exposed aggregate was still a bit too spalled. After quickly smoothing out this area in between coats of Uroflex, the 2nd coat was immediately started.

Again, this advantage cannot be overstated, having the ability to further detail any repairs in between coats is a huge advantage; whereas, many other systems are too committed, and once they are applied, many loose their recoat window fast or simply just do not have the properties to allow for in-between filling or patching. In fact, with Uroflex, some applicators simply skip bughole filling, intentionally let bugholes appear as they apply the first coat, and then patch in between coats. This way an applicator does not have to guess what may get covered by the coating, rather, whatever the coating does not cover, simply fill the bugholes in later after the first coat, then continue forward with the second. This can in deed save time, money and guessing work - offering an unique option to certain logistics during application.

The final coat of Uroflex is then applied.

Note: the pictures above highlights the red Uroflex coating being applied in one single coat.

Some structures at Miami-Dade have been applied with two coats of Epoxytec Uroflex typically at 25 mils per coat. In other cases, especially when spraying, Miami-Dade has applied 1 coat at 30 - 40 mils. Epoxytec recommends its Uroflex performance for sewer to be suitable at 30 mils minimum, the only other reason to increase thickness is typically for profile coverage, thus going thicker to cover stubborn aggregate exposed concrete profiles.

Picture of completed UNOX tank rehab and protection with Epoxytec Uroflex (30 - 50 mils on various structures, dependant of different conditions).

Once the interior tank surfaces are completed (rehabilitated and protected) the agitator plates are reset and sealed (along with concrete joints) with Epoxytec Uroseal 45V (100% urethane) in order to resist chemical attack to the joints and also to disallow oxygen from escaping.

Epoxytec Uroflex - Successfully Servicing Sewers

2008-12-23T16:09:00.028-05:00

A prime example of quality industry – specific formulations provided by Epoxytec is a proprietary hybrid blending of epoxy and urethane. The result is a potent chemical combination providing the superior adhesive qualities and structural strength of epoxies as well as the flexibility and fluidity associated with urethanes. Once applied, Uroflex establishes a barrier liner capable of resisting debilitating chemical deconstruction and corrosion while simultaneously supplying increased impact resistance and structural strength.

The end result of a Uroflex application is a sewer system with enhanced structural integrity, thus sealing and protecting the concrete or steel from ultra high H2S and other types of corrosion. Coated systems are capable of resisting the deterioration that results, over time, from the shifting of concrete or steel sub-strata structures. Accompanying the enhanced performance and reliability comes a durability that extends the service life cycle of sewer systems beyond established industry expectations. Uroflex is a true hybrid among the pack. Having a hybrid advantage allows for better specification designing by controlling the advantages found in hybrid coating designs.

This industry has unfortunately experienced many problems that in some cases led to failures because of generalized designing and irresponsible product submittals with inferior broad-ranged products not designed for sewer. The solution is specifying sewer-specific coatings, and none is better than a proven hybrid coating to resist corrosive environments and possessing the proper performance properties required in that environment. Uroflex is that hybrid solution – it is unique, specific, and proven.

A Case In Point: Miami-Dade Water & Sewer

Current Uroflex applications administered under Epoxytec’s expert supervision exist across a wide range of states and regions. Included in this is over 2,000,000 square feet of sewer systems in Miami-Dade alone, where this custom formulation has proven its reliability and durability since 1990. A noteworthy inspection conducted in the Fall of 2000 by the highly regarded engineering firm of Hazen & Sawyer attests to the effectiveness and reliability of Uroflex applications in UNOX tanks (closed anaerobic digesters), one of the harshest industrial environments in existence. These closed oxygenation trains breed microbial attack (and its sulfuric byproduct) and other types corrosion, resulting from high heat chemical gases reacting to agitated erosion activities and periodic oxygen injections. In an exceedingly more hostile and debilitating environment than most, Uroflex proves its quality every single day.

Ensuring a Solid Return on Investment
Reliability and durability are obvious performance-related benefits of applying Uroflex in restorative or maintenance situations. The hidden benefit in Uroflex applications is financial. Although actual numbers may vary, typical industry costs for coating applications and operations account for only a small percentage (4% on average) of most capital project or maintenance budgets. When structural deterioration or contamination due to corrosion or other invasive conditions occurs, the costs to repair sewer systems can easily run into millions of dollars. Funds for such extensive repairs can be hard to come by, even in times of relative economic stability. The proper application of Uroflex linings, performed under the expert guidance of our certified technicians and applicators, sets up a strong protective shield, preventing structural deterioration and system failure. The application of Uroflex on sewer system structures gainfully prolongs the service life cycle of such systems. Considering that such applications can cost as little as 4% of most representative repair estimates, it is easy to see that the value of a designed preventive maintenance solution specifying Uroflex should be considered to proactively prevent costly structural failures from happening. Uroflex is a product offering a solid return on investment as well as significant long-term savings.

The One Right Choice: Epoxytec
Three qualities set the custom formulations designed and supplied by Epoxytec apart from the rest: superior quality, extraordinary performance, and exceptional value. Once you experience the difference our products, people and service can make in your preventative maintenance and rehabilitation projects, we believe you will see that the hallmark of our work is excellence. Our customers know that, when every dollar counts and time is of the essence, they can turn to us for quality solutions providing exceptional performance. We are their problem solvers.

The benefits of enlisting Epoxytec for your next project are many. Here are just a few:

» Research-based specific solutions developed for industry specific applications.
» Easy application methods and simplified maintenance.
» Certified, veteran technicians and applicators.
» Active participation with industry specific organizations, such as NACE and SSPC.
» A management team with industry experience since 1979.
» Extended service life cycles for concrete and steel structures.

We think you’ll agree it’s an impressive list. Epoxytec delivers these benefits - and more - to our clients every day. Our commitment to you is quality and excellence. We look forward to discussing opportunities with you. Call today.