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Flexible Coating and Lining SystemConcrete Potable Water Tank Rehabilitation1.00GENERAL1.01ScopeA.1.02This specification covers the work necessary to furnish and install a 100% solidspolyurethane elastomer such as Sher-flex, Silkaflex, etc or equivalent concretepotable water tank rehabilitation and lining system, as shown on the drawingsand as specified herein. Work includes, but is not limited to, the following.1.Stopping Leaks by repair and sealing of the concrete to include removalof unsound and unbonded materials, chemical grouting, patchingcompounds, resurfacing compounds, and plugging compounds.2.Surface preparation, and installation of the Polyurethane ElastomerLining System such as Sher-flex, Silkaflex or equivalent, to includeprotection of surfaces not to be treated, touch-up, clean-up, andappurtenant work all in accordance with the requirements of the ContractDocuments and this Specification.3.Surface preparation and protective coating of miscellaneous exposedstructural and mechanical metals at the interior of the concrete tank.Referenced Specifications Codes and StandardsA.Without limiting the generality of other requirements of these specifications, allwork hereunder shall conform to the applicable requirements of the referencedportions of the following documents, to the extent that the requirements thereinare not in conflict with the provisions of this Section. All references andstandards listed shall be the latest revisions. Joint and individual documents arereferenced.1.SSPC – The Society for Protective Coatings40 24th Street, 6th FloorPittsburgh, PA 15222-4643(412) 281-23312.NACE – National Association of Corrosion EngineersP.O. Box 218340Houston, TX 77218-8340(281) 492-0535a.b.c.d.e.f.SSPC-SP 13/NACE No. 6 Surface Preparation of ConcreteSSPC-SP10/NACE No. 2, Near White Metal Blast CleaningSSPC-PA9, Measurement of Dry Coating Thickness onCementitious Substrates Using Ultrasonic GagesNACE RP0892 “Linings over Concrete for Immersion Service”NACE SP0188 “Discontinuity Holiday Testing of ProtectiveCoatings”NACE RP 6F-164 “Curing of Interior Tank Linings”Concrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 1of 126/20//17
Flexible Coating and Lining SystemConcrete Potable Water Tank Rehabilitationg.3.ICRI – International Concrete Repair Institute1323 Shepard Dr., Suite DSterling, VA 20164-4428(703) 450-0116a.b.4.Technical Guideline No.310.2R, “Selecting and SpecifyingConcrete Surface Preparation for Sealers, Coatings, and PolymerOverlays”Technical Guideline No. 0310.2R, “Guide for Selecting ApplicationMethods for the Repair of Concrete Surfaces”ASTM – American Society for Testing and Materials100 Barr Harbor DriveWest Conshohocken, PA 19428-2959(610) 832-9585a.b.c.e.f.g.h.i.j.5.NACE RP 6F-166 “Recommended Practice for Inspection ofLinings on Steel and Concrete”ASTM D4263 Standard Test Method for Indicating Moisture inConcrete by the Plastic Sheet MethodASTM E-337: Test Method for Measuring Humidity with aPsychrometerASTM D 4258 “Practice for Surface Cleaning Concrete forCoating”ASTM D 4262 “Test Method for pH of Chemically Cleaned orEtched Concrete Surfaces”ASTM D 4414 “Standard Practice for Measurement of Wet FilmThickness by Notch Gages”ASTM Committee D01.23: Test Method for NondestructiveMeasurement of Dry Film Thickness of Applied Organic CoatingsUsing an Ultrasonic GaugeASTM D 4541 “Standard Test Method for Pull-Off Strength ofCoatings Using Portable Adhesion Testers”ASTM D 4787 “Standard Practice for Continuity Verification ofLiquid or Sheet Linings Applied to Concrete Substrates”ASTM D 5162 “Standard Practice for Discontinuity (Holiday)Testing of Nonconductive Protective Coating on MetallicSubstrates”ACI – American Concrete InstituteBox 19150, Redford StationDetroit, Michigan 48219(248) 848-3700a.b.ACI 350R-01 Requirements for Environmental EngineeringConcrete StructuresACI 350.1 “Testing of Reinforced Concrete Structures for WaterTightness”Concrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 2of 126/20//17
Flexible Coating and Lining SystemConcrete Potable Water Tank Rehabilitationc.d.e.6.ACI 350.2 “Concrete Structures for Containment of HazardousMaterial”ACI 503 “Use of Epoxy Compounds with Concrete”ACI 504 “Guide to Sealing Joints in Concrete Structures”AWWA – American Water Works Association6666 West Quincy AvenueDenver, Colorado 80235(303) 794-7711a. ANSI/AWWA C652 “Disinfection of Water Storage Facilities”7.ANSI – American National Standards Institute1899 L Street, NW, 11th FloorWashington, DC 20036(202) 293-8020a. ANSI/NSF Standard 61 “Drinking Water System Components”1.04SubmittalsA.1.05Submit product data for each component specified including data substantiatingthat the proposed materials comply with specified requirements andrecommendations by the manufacturer covering all materials.Quality AssuranceA.Acceptable Manufacturers: The manufacturer of the specified products shallhave in existence, for a minimum of five (5) years, a program of training,certifying and technically supporting a nationally organized Approved ContractorProgram with annual recertification of its participants. Manufacturer mustprovide five (5) project histories with names, dates, addresses, and phonenumbers of contact persons for projects of similar scope, two of which have beencompleted at least three (3) or more years ago.B.Single Source Responsibility: Provide primers and undercoat materials producedby the same manufacturer, or recommended by manufacturer, for each type ofSpecial Coating / Lining specified to ensure compatibility, and proper chemicaland mechanical bond.C.Installer Qualifications: Engage only factory trained and qualified applicator thathave successfully completed applications using specified materials on projects ofsimilar size and scope. Provide references with name, address, and telephonenumber.1.Contractor shall have completed an approval program in the use ofheated plural component equipment and the specified polyurethaneelastomer material such as Sher-flex, Silkaflex or equivalent. ProvideConcrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 3of 126/20//17
Flexible Coating and Lining SystemConcrete Potable Water Tank Rehabilitationwritten certification from the material manufacturer that the contractor isan approved contractor of the system specified.D.E.Equipment Requirements:1.Correct material processing equipment is critical in achieving correct mix forthe plural component system specified.2.Equipment must be heated plural component unit capable of consistentlyooproducing 4000 psi, at 140 F to 160 F.3.Acceptable pumps and spray gun: Graco Hydra-Cat, Graco XP50/XP70,WIWA Duo-Mix. Equivalent application equipment may be substituted andmust be approved in writing by the manufacturers Technical Service Group.Substitutions:1.F.E.1.06Manufacturers seeking approval of products other than the materialsused as the basis of design must supply cured samples, full productinformation, project histories and references, technical data withspecifications, SDS, and certifications regarding conformity ofperformance properties from an independent testing laboratory. Theproduct being submitted for approval must meet all requirements of theperformance properties specified within this specification. Compliancewith the above quality assurances must be provided in written form atleast fourteen (14) days before bids are received. Omission or nonconformance of any item will result in rejection of the request.Pre-Installation Conference1.The contractor, the installation sub-contractor, and the concrete tanklining system manufacturer’s representative shall meet on site with theowner’s representative. Particular emphasis shall be placed on thesespecifications, safety, weather conditions, surface preparation, materialapplication, and inspection.2.The contractor shall submit to the owner’s representative any revisions orchanges agreed upon, reasons thereof, and parties agreeing ordisagreeing with them.Substrate Conditions: Do not proceed with work until substrate preparation andtolerances have been approved by the owner’s representative, concrete tanklining system manufacturer’s representative, the approved installation subcontractor, and the contractor.Delivery, Storage, and HandlingA.Deliver products to the job site in manufacturer’s original, unopened containersbearing manufacturer’s name and label and the following informationConcrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 4of 126/20//17
Flexible Coating and Lining SystemConcrete Potable Water Tank Rehabilitation1.2.3.4.B.Product nameProduct description (generic product classification)Manufacturer’s lot numberColorStore materials in sealed original manufacturer’s containers. Store materials in aprotected area out of direct sunlight. Keep containers clean and undamaged.Adhere to manufacturer’s published storage temperature and shelf liferecommendations. Protect all materials from freezing.2.00PRODUCTS2.01Acceptable Manufacturers and MaterialsA.The Polyurethane Elastomer Lining System such as Sher-flex, Silkaflex orequivalent shall consist of one or more systems for concrete repair and corrosionprotection. Products are specified as a standard of quality, and aremanufactured or distributed by The Sherwin-Williams Company, Cleveland,Ohio.1. Stopping Leaks - Infiltration leakage of all concrete shall be stoppedby trenchless technology method of chemical grouting withpolyurethane grouts. Products shall be manufactured by AvantiGrouts or equivalent and shall be classified as “Hydrophobic Foam”,“Hydrophilic Gel” or “Hydrophilic Foam” grouting compounds or acombination of these materials and methods as recommended bythe manufacturer.Hydrophobic Polyurethane Grouts are hydrophobic polyurethanesthat when mixed and makes contact with the water, is designed tofill large voids in rock fissures, gravel layers, and cracks in concretestructures and for the cut-off of gushing water.Avanti Grouts AV-280 Hydrofoam with AV-281 HydrocelProperties - UncuredAppearance: Amber liquidViscosity: 1700-2000 cP @ 72 FFlash Point: 200 FSpecific Gravity: 1.14Weight: 9.49 lbs/gal /- 3%Properties – CuredAppearance: Pale yellow rigid foamToxicity: Non-ToxicHydrophilic Polyurethane Gels are hydrophilic polyurethanesdesigned to react with water and form a water impermeable gelmass. When they come into contact with water, the grout begins toConcrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 5of 126/20//17
Flexible Coating and Lining SystemConcrete Potable Water Tank Rehabilitationfoam and gel, and depending on the temperature and amount ofwater present, quickly cure to a flexible, impermeable foam or gelmass unaffected by mildly corrosive environments.Avanti Grouts AV-202 Multi-GroutProperties - UncuredAppearance: Brown resinViscosity: 3200-6000 cP @ 72 FFlash Point: 200 FSpecific Gravity: 1.147Weight: 71.7 lbs/ft³ /- 3%Properties – CuredAppearance: Milky colored flexible foamHydrophilic Polyurethane Foams are designed to form a flexiblegaskets or plug in joints and cracks in concrete. When it comes intocontact with water, the grout expands quickly and cures to tough.flexible, adhesive, closed-cell, foam that is essentially unaffected bymildly corrosive environments.Avanti Grouts AV-202 Multi-GroutProperties - UncuredAppearance: Brown resinViscosity: 3200-6000 cP @ 72 FFlash Point: 200 FSpecific Gravity: 1.147Weight: 71.7 lbs/ft³ /- 3%Properties – CuredAppearance: Milky colored flexible foamHydrophobic Polyurethane Grouts that are designed to form flexiblegasket or plugs in very tight joints and hairline cracks. When theycome into contact with water the grout expands and depending ontemperature and the amount of accelerator used quickly cures to atough, flexible closed cell polyurethane foam that is essentiallyunaffected by corrosive environments.Avanti Grouts AV-248 Flexseal LV with AV-249 Catalyst LVProperties - UncuredAppearance: Milky white to clearViscosity: 550-830 cP @ 72 FFlash Point: 200 FSpecific Gravity: 1.056Weight: 8.8 lbs/gal /- 3%Properties – CuredAppearance: Milky white flexible foamToxicity: Non-ToxicConcrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 6of 126/20//17
Flexible Coating and Lining SystemConcrete Potable Water Tank Rehabilitation2. Resurfacing Materials – Designated structures shall receive anapplication of resurfacing compounds/repair mortar. The resurfacingcompounds/repair mortars are classified as Hydraulic Cements orMicrosilica Repair Mortars. Microsilica Repair Mortars shall bedesignated for areas of substrate depth loss of ¼”-2” in a single liftand to be top coated with the polyurethane elastomer such as Sherflex, Silkaflex or equivalent lining system as shown on the drawings.Thickness shall be sufficient to replace lost cross section and fillvoids.Hydraulic Cements shall be cement based, quick setting, hydrauliccement compound which instantly stops weeping water throughconcrete or masonry walls and floors. They will become harder andmore resistant when subjected to constant water pressure. (Usedprimarily for filling large voids and stopping minor weeping waterleaks)A.W. Cook Cement, CEMTEC Hydraulic CementPhysical Properties (28 day cure)Compressive Strength ASTM C-1095,500 psiTensile Strength ASTM C-496650 psiBond Strength ASTM C-882 (Modified)880 psiSetting Times (Gilmore) “Hot Mix”65 secondsRapid Cure Vertical Grade repair mortars shall be a one part,polymer modified, fast setting, silica fume, fiber reinforced mortardesigned for vertical and overhead repairs from ¼” to 2” in one lift.The product may be applied by hand trowel or sprayed with a lowpressure pump. (Used to hand place large voids, bench repair, orhand troweled structural wall linings)A.W. Cook Cement, CEMTEC Silatec Rapid Cure Vertical GradePhysical Properties (28 day cure)Compressive Strength ASTM C-1096,800 psiFlexural Strength ASTM C-293990 psiBond Strength ASTM C-882 (Modified)1,600 psiShrinkage ASTM C-5960.07%Abrasion Resistance – ¼” APCI1Setting Times @ 77 FInitial Set – 35 minFinal Set – 50 minMicrosilica repair mortars shall be a blend of Portland cement,graded silica sand, fibers and silica fume. The mortar may be handtroweled or spray applied, usually from ½” to 1” in depth. Usesinclude repairing concrete walls, ceilings, lining brick or concretemanholes and lift stations, etc. Microsilica repair mortar provides anextremely dense matrix and will accept coatings at earlier ages thanConcrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 7of 126/20//17
Flexible Coating and Lining SystemConcrete Potable Water Tank Rehabilitationtypical Portland cement repair products. (Used primarily forstructural wall linings)A.W. Cook Cement, CEMTEC Silatec MSMPhysical Properties (28 days cure)Compressive Strength ASTM C-109Flexural Strength ASTM C-293Shrinkage ASTM C-596Freeze/Thaw ASTM C-666 100 cyclesBond Strength ASTM C-882 (Modified)Modulus of Elasticity ASTM C-469Tensile Strength ASTM C-4962.0210,400 psi1,695 psi0.00%No Effect1,695 psi4,533,333 psi750 psi3.Concrete Crack and Joint Details – Exposed cracks, construction joints,contraction joints, and isolation joints shall be prepared, filled anddetailed in accordance with the attached detail drawings. All Sealantsshall be ANSI/NSF Standard 61 approved. Should any conditions or jointdesign be discovered that is not detailed in the attached drawings, thecontractor shall notify the owner and consult with the materialmanufacturer for recommendations.4.Miscellaneous Metals Lining System: All interior concrete tank exposedmetal surfaces shall receive application of Sher-flex, Silkaflex orequivalent polyurethane elastomer ining system.5.Concrete Tank Lining System: All interior concrete tank surfaces shallreceive application of Sher-flex, Silkaflex or equivalent polyurethaneelastomer lining system.Performance CriteriaA.The concrete potable water tank lining system shall be ANSI/NSFStandard 61 approved material for Drinking Water Components.B.The concrete tank lining system shall be resistant to cracking fromconcrete shrinkage and atmospheric thermal movement at constructionjoints and contraction joints up to 1/8” at temperatures down to 00 F.C.Physical PropertiesPROPERTYTEST METHODRESULTSAdhesionASTM D4541Concrete failureSteelASTM D-638ASTM D-638350psi1,800 psi37%1800 psiTensile ElongationTensile StrengthConcrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 8of 126/20//17
Flexible Coating and Lining SystemConcrete Potable Water Tank RehabilitationShore D HardnessASTM D-224068Flash PointSolids by VolumeWater Vapor Permeance 200 F100%20.574grains/hr ft HgASTM E-96Abrasion ResistanceASTM D-4060, CS-17106.0 mg.lossGardner ImpactASTM D-2794Direct(Applied to 1/32" steel panels) 160 in-lbs.Mandrel BendASTM D-17378 mm Conical bendPass(20 mils applied to .5mm steel panels)Thermal Conductivitycal./sec.cm² C per cm at 20 C(BTU/HR.ft. F per ft at 77 F)ASTM C-1773.00EXECUTION3.01Surface PreparationA.0.000550 cal(0.133 BTU)Concrete1.The NACE/SSPC Joint Surface Preparation Standards for concretesurface preparation are incorporated in and made part of thisspecification. All references to SSPC-SP-13/NACE No.6, designate thedefinitions and other requirements in theses documents. TheInternational Concrete Repair Institute (ICRI) Technical Guideline No.0310.2R, Guide to Surface Preparation of Concrete to Receive Sealers,Coatings and Polymer Overlays shall be used to visually evaluate theconcrete surface profile.2.Inspect concrete surface for soundness, flatness, levelness and overallcondition. Report any discrepancies to the owner’s representative.3.Create a minimum surface profile in the host substrate for the concreterepair and resurfacing in accordance with the methods described in ICRINo. 0310.2R to achieve substrate surface profile numbers CSP-5 toCSP7. After installation of the concrete repair and resurfacing materialscreate a minimum surface profile for the lining system specified inaccordance with the methods described in ICRI No. 0310.2R to achieveprofile numbers CSP-3 to CSP-5.Concrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 9of 126/20//17
Flexible Coating and Lining SystemConcrete Potable Water Tank Rehabilitation4.Following host substrate surface preparation, concrete surfaces shall betested for the presence of moisture in accordance with ASTM D4263Standard Test Method for Indicating Moisture in Concrete by the PlasticSheet Method only if deemed necessary. Report results to owner orowner’s representative. If this step is not deemed applicable/necessary,the proposed cost for this task will be credited to owner or ownersrepresentative.5.Stop concrete leaks and infiltration at cracks and joints by use ofpolyurethane injection grouting through trenchless technology applicationmethods.6.Concrete Surface Repair: Bug holes, honeycombs and voids7.B.a.Areas less than 1/4” deep shall be repaired with Steel-SeamFT910 epoxy patching and surfacing compound or A.W. CookCement repair mortars or approved equal.b.Areas that are greater than 1/4” deep shall be repaired with A.W.Cook Cement repair mortars or approved equal.Provide a clean, saturated surface dry (SSD) concrete surface with nofree standing or glistening water, with a minimum surface profile aspreviously defined. SSD is defined as the capillary pores of the cementmatrix and pores of the aggregate in the concrete matrix being saturatedwith water but the surface of the substrate shall be visibly dry with nostanding or glistening water. All substrates are to be vacuumed, sweptand blown down with clean, dry air to remove spent abrasive, dust andother foreign material that might interfere with the adhesion of the primerand lining.Iron and steel1.The NACE / SSPC Joint Surface Preparation Standards for abrasiveblasting approved in October 1994 are incorporated in and made a part ofthis specification. All references to SSPC-SP10 / NACE No. 2 designatethe definitions and other requirements in these documents. SSPC VIS 189 Visual Standard for Abrasive Blast Cleaned steel shall be used tovisually evaluate the blast cleanliness.2.Remove all oil, grease, soil, drawing and cutting compounds, and othersoluble contaminants from surface by solvent cleaning per SSPC-SP1.Minimum surface preparation is SSPC-SP10 / NACE No. 2, Near WhiteMetal Blast Cleaning. Abrasive blast clean all surfaces using a sharp,angular abrasive for optimum surface profile (3-4 mils). Prime any baresteel the same day as it is cleaned and before flash rusting occurs.Concrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 10of 126/20//17
Flexible Coating and Lining SystemConcrete Potable Water Tank Rehabilitation3.02a.Inspect the surfaces to be lined. All holes in the steel surfaces orpits greater than 1/8 inch shall be repaired in accordance with thetank owner’s repair procedures.b.Remove or grind down all sharp burrs, edges, and weld spatterfrom all steel that is to be coated. Corners and edges shall bechamfered 1/16” at a 45 angle minimum or rounded to a 1/16”radius (1/8” diameter) minimum. The anchor profile shall berestored by abrasive blasting prior to the application of liningmaterials.c.All substrates are to be vacuumed, swept and blown down withclean, dry air to remove spent abrasive, dust and other foreignmaterial that might interfere with the adhesion of the primer andlining.d.The maximum allowable residual salt contamination, as measuredwith a KTA Scat Kit or equivalent field test method, immediatelyprior to the application of the first coat is as follows:2 5 micrograms per square centimeter (50mg/m ) mostocommodities up to 120 Fe.Corrosion pits in the blasted steel shall be filled flush with thesubstrate with Steel-Seam FT910 epoxy patching and surfacingcompound putty/patching and surfacing compound.f.Projections and lap joints on welded plates and on riveted platesto be coated shall be filled with Steel-Seam FT910 epoxy patchingand surfacing compound putty/patching and surfacing compoundin order to smooth out the surface and provide for a smoothtransition of the lining over the substrate.ApplicationA.Comply with manufacturers written installation procedures, individual productdata sheet, application bulletins and detail drawings.B.Apply materials in accordance with the following material coverage.Approved Polyurethane Elastomer Tank Lining System (e.g. Sher-flex, Silkaflex orequivalent)ProductsPrimerDura-Plate 235 Multi-Purpose EpoxyRepair/Patching and surfacing CompoundSteel Seam FT910Concrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 11of 12Thickness (mils dft)5.0-7.0As needed6/20//17
Flexible Coating and Lining SystemConcrete Potable Water Tank RehabilitationRepair MortarsStopping LeaksAs neededAs neededFlexible Coating/LiningSher-flex, Silkaflex or equivalent Polyurethane ElastomerConcrete Water Storage TankMiscellaneous Steel80.0 – 100.030.0 – 50.085.0 – 107.0Total Dry Film Thickness3.03 Inspection and TestingA.The owner or owner’s authorized representative may require the services of anindependent testing laboratory to test the installed system.B.If test results indicate noncompliance with the specification, the followingcorrective action may be required of the contractor1.2.3.C.Minimum requirements of the Sher-flex, Silkaflex or equivalent polyurethaneelastomer lining system are that it be free of the following1.2.3.4.5.6.D.3.04Remove non-compliant systems or components.Replace system or components in (1)Assume the testing expenses.Uncured material per visual and physical inspectionInadequate thickness per SSPC PA-9Pinholes per NACE SP0188Blisters per ASTM D714Foreign matter per visual inspectionUnspecified materials per QA/QC DocumentationThe lined surface of the potable water storage tank shall be disinfected per therequirements of AWWA C652 prior to the storage of water. After disinfectionthere shall be no one permitted to make entry in to the tank. Entry in to the tankafter disinfection shall require this process to be repeated.ProtectionA.The Sher-flex, Silkaflex or equivalent Polyurethane Elastomer Lining Systemshall be protected from damage or detrimental elements during cure and until thetime of final acceptance.End of SectionConcrete Potable Water Storage Tank Rehabilitation Specification 062217.docPage 12of 126/20//17
Concrete Potable Water Tank Rehabilitation Concrete Potable Water Storage Tank Rehabilitation Specification 062217.doc 6/20//17 Page 2of 12 g. NACE RP 6F-166 "Recommended Practice for Inspection of Linings on Steel and Concrete" 3. ICRI - International Concrete Repair Institute 1323 Shepard Dr., Suite D Sterling, VA 20164-4428 (703) 450-0116
