IntroductionMany chambers are by definition confined spaces, and so Ultracoat is the ideal solution when chamber rehabilitation is required. No breathing apparatus is necessary, and so the complexity of a project is kept to a minimum.
Chambers are also often used for storage of highly corrosive chemicals. Whether brewery waste, cleaning agents, or any other substance between pH 2 and 14, Ultracoat can be used safely and reliably. An initial assessment is always carried out and a long term guarantee of longevity is always provided.
Large Chamber Raw Water Storage Tank project - Bethlehem, New YorkChallenge facedThe steel tank was built in the 1970’s and was not coated but had been fitted with cathodic protection system which apparently had not worked correctly. The interior wall of the clarifier was uniformly pitted to a depth of 3mm and rust had penetrated to a depth of 6mm. Stratified rust between 6mm and 18mm covered the interior walls. Once cleaned the surface appeared scalloped, the rust in some places penetrating the tank walls.The client considered three options; Total replacement of clarifier with stainless steel structure, Painting with NSF approved coating and the installation of cathodic protection or using a NSF approved structural epoxy coating – Ultracoat to restore the integrity of the damaged steel. The client chose the third option as it negated the requirement for cathodic protection - which had previously failed.About the projectThe tank measures 4.2m deep by 15m diameter . To ready the interior of the clarifier for coating the rust was removed and the surface was prepared to SSPC-SP 5 , white metal finish with a 4 mil profile by abrasive blasting.The tank was then washed down and allowed to dry overnight. The flash rusting was removed next morning by blasting with dustless polishing staurite abrasive media.Ultracoat structural epoxy primer was then spray applied to the walls at a thickness of 1mm .An intermediate coat of fibre reinforced Ultracoat structural epoxy was then applied to a thickness of 6mm. ( In tests structural epoxy has a yield strength of 10,000 psi at this thickness – the same as 6mm thick aluminium)The top coat a third formulation of the cycloaliphatic epoxy was was applied at a thickness of 2mm.SummaryThe job was completed within the budgetary and timescale parameters agreed and on completion pull tests indicated adhesion of Ultracoat at over 1000psi and no delamination was observed.In addition to the cost savings achieved the client saved time once the project was complete. Because Ultracoat structural epoxies have no solvents the client could immediately fill the tank once washed down with chlorine.
- 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