IntroductionAfter initial successes with manhole rehabilitation, Ultracoat has more recently been used with great success for culvert surfacing and repair. Below shows a recent success in Tasmania, on a hydroelectric flume. See our Case Study section for more images and additional project details.
On large surface areas, Ultracoat is ideal due to its speed of application. Efficiency of application is also improved as no primer coat is required, and on damp substrates such as that pictured, Ultracoat will adhere to the surface without issue. No costly drying procedure is needed.
Whether in prolonged contact with acidic or alkaline chemicals, potable or wastewater, use of Ultracoat for rehabilitation of culverts is an ideal solution.
THE LIAWENEE FLUME REHABILITATION PROJECT, TASMANIA
The Liawenee Flume is situated high in the mountains north of Hobart, the capital city of Tasmania, an island 180 miles south of Australia.
We were asked by Hydro Tasmania, a short time after we had presented the Ultracoat system, if we were interested in a trial job coating a flume that carried water from the Ouse River onwards via a canal to The Great Lake. The Great Lake services 3 hydro electric power stations, part of the 10,000 gigawatt hour generating capacity of Hydro Tasmania.
The flume needed repairs to the damaged and eroded concrete surface, and the new coating would also need to improve the hydraulic capacity ( flow rate).
The flume was a cast in place concrete ‘U’ section with 10 foot walls and a 12 foot base. The surface was significantly eroded by the water flow and freeze thaw damage. The surface was extremely coarse being an exposed Dolerite aggregate, very sharp and very hard. There was also significant moss growth that would have to be removed.
Interestingly it was in the height of the Tiger snake mating season and the site was surrounded by kangaroos, wallabies, wombats and platypus (we saw them all!)
The Ultracoat system and accessories were shipped from the UK by boat over 12,000 miles to Hobart, Tasmania. After arriving we hired a small truck and a large station wagon, loaded up and set off up the mountain.
The first task was removing the moss, growths and unsound areas from the surface with a high pressure jet washer, and in more difficult areas with a pneumatic scabbler. For the next stage we sprayed the whole area to be coated with a dilute bleach as a mild biocide and thoroughly washed down with copious amounts of water. We followed this with a dilute acid wash to remove carbonates and calcium deposits in the concrete surface, this was again followed by a thorough wash down with water.
Ultracoat is applied at 65 degrees Celsius and due to its thixotropic characteristics Ultracoat can be applied in a single coat up to 8mm thick with no runs or slumping. The standard coating thickness is 6mm.
A movie showing this case study in more detail can be viewed in the Video Demonstration section of Culverts.
- 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