Bund Lining - Ultracoat System
The Ultracoat system has been used for the rehabilitation of over 50,000 manholes worldwide, and is increasingly used for bund lining and other asset management projects.
With the introduction of ISO 14001, all bunded areas must now be completely impermeable to all liquids they may be required to house. This requires a waterproof coating, and also a coating with high level of chemical resistance.
Case StudiesFuel Bund - Manchester
Challenge FacedThe mainly brick built fuel bund was built in the 1970s and did not meet the required standard to comply with ISO 14001.
There were numerous areas of the walls in poor repair and the concrete base was in poor condition. The client had the option of rebuilding the bund or lining it. Ultracoat was chosen due to its excellent bonding characteristics, high chemical resistance and the speed of application.
About the ProjectThe bund measured 12m x 4m with a 0.7m high wall . To ready the interior of the bund for coating all loose debris and vegetation was removed. The surface of the brickwork was then prepared by abrasive blasting to expose solid substrate. The bund was then degreased followed by acid etching to remove laitance and sulphates from the surface.
Local repairs were undertaken using fast set cement.
The Ultracoat structural epoxy was then spray applied to a thickness of 4mm in a single coat. The epoxy was then struck off using a float to force the resin into the mortar joints.SummaryWeather conditions were severe during the project reaching -7°C at one stage.However Ultracoat performed to its usual high standard and job was completed within the budgetary and timescale parameters agreed and on completion pull tests indicated adhesion of Ultracoat at over 800psi and all failures occurred within the substrate.
The structure was accepted by the Environment Agency as a waterproof structure.
- Structurally reinforces corroded structures or weakened substrates
- No harmful VOCs (Volatile Organic Compounds) - safe for use in confined spaces, addressing many Health and Safety issues.
- Proven adhesion to damp substrates
- Up to 50 year project guarantee provided
- Over 20 epoxy matrices available; for potable water, fast cure, flexible, fire retardant, high build, gloss finish and others.
- Numerous independent test results and accreditations
- Monolithic coating, with no primer required - quick application
- Superb chemical resistance from pH 2 to 14 including high levels of H2S
- Very high build thickness without slumping - up to 20mm in one application.
Third Party Testing
Independent test reports from the IKT, the US Navy, the Concrete Products Association and from several other independent testing houses are available on request.
The Ultracoat system has been tested to the following standards
ASTM C297 - Tensile Strength
ASTM D2240 - Durometer Hardness
D2584 Volatile Matter Content.
D4414 - Wet Film Thickness by Notch Gages
D4541 Pull-off Strength of Coatings Using a Portable adhesion Tester.
D4541 - Concrete Failure Chemical Resistance to: Sulfuric Acid, 70%
D543 Resistance of Plastics to Chemical Reagents.
D543 Water Vapor Transmission of Organic Coating Films.
D543 - Immersion Service
D638 Flexural Properties of Unreinforced and Reinforced Plastics
ASTM D638 Tensile Properties of Plastics.
ASTM D638 - Flexural Strength
ASTM D638 - Tensile Elongation
ASTM D638 - Tensile Strength
ASTM D695 Compressive Properties of Rigid Plastics.
ASTM D695 - Compressive Strength
ASTM D695 - Flatwise Tensile Strength Of Sandwich Constructions
ASTM D790 Flexural Properties of Unreinforced and Reinforced Plastics.
ASTM D790 - Bond Strength Concrete
ASTM D790 - Flexural Modulus
ASTM D790 - Flexural Strength
ASTM E84 - Test Method for Surface Burning Characteristics of Building Materials