2022 Prestige Awards Winner: Concrete Coatings
The annual JPCL Prestige Awards program recognizes influential individuals, impactful products on the market and noteworthy projects completed during the past year in the protective and marine coatings industry.
Differing from past editions, the 2022 Top Project Awards highlight specific products involved in notable coating projects across an array of industry sectors, including bridge and highway, water and wastewater, marine, energy production and more.
Additionally, each Top Project category includes Project MVP awards, which recognize the team leaders who helped carry these projects through to successful completion.
“We wanted to enhance this year’s Prestige Awards by assessing the performance of top products and the influence of outstanding individuals on real-world, high-stakes painting projects,” said Charlie Lange, Editor-in-Chief, JPCL.
“By recognizing the team leaders and the materials and equipment used to complete these projects, we’re offering a 360-degree view of the jobs from start to finish, and truly focusing on the critical components that led to the project’s completion.”
Over the coming weeks, PaintSquare Daily News will be highlighting the winners of this year’s projects. A full list of winners can be found in the January edition of the Journal of Protective Coatings & Linings.
Nominations for the 2023 Prestige Awards are anticipated to open later this spring.
The Concrete Coatings award was given for a coatings project on a concrete structure. The project can involve application of new coatings technologies, and/or involve application on a particularly complicated or challenging structure. Any specialized surface preparation or inspection techniques should also be highlighted, along with the coatings systems used and project challenges.
Concrete Coatings Winner
The Upper Skokie Valley Pumping Station PS-5 plays a critical role in the conveyance of domestic wastewater for the North Shore Water Reclamation District. Constructed in early 1970s, this cast-in-place Portland cement concrete structure was experiencing attack section loss from years of exposure to biogenic sulfide corrosion—a type of corrosion that commonly occurs in wastewater infrastructure.
This project consisted of surface preparation, concrete repairs and epoxy coating of the two wet wells and screen channels. Concrete degradation ranged anywhere from 2-8 inches to the horizontal, vertical and overhead surfaces of both the screen channels and wet wells. In fact, shoring was required during rehabilitation to support the concrete structure while new reinforcing steel and structural repair work was performed.
Consulting engineer Baxter & Woodman, Inc. specified Tnemec’s Series 217 MortarCrete cementitious repair mortar for the 2-8 inches of repair to the horizontal, vertical and overhead surfaces. Series 217 MortarCrete is a specialty, rapid setting, calcium sulfoaluminate (CSA) cement with enhanced corrosion resistance over traditional Portland cement repair mortars. Series 217 can be applied 4 inches or greater in a single lift to vertical and overhead surfaces and achieve full compressive strength properties in 24 hours. Series 218 MortarClad epoxy cementitious resurfacer was applied over the Series 217 to fill any surface cracks and help level the substrate for topcoating.
The Series 217/218 repair work was protected by the specified topcoat system with Tnemec’s Series 434/435 Perma-Shield H2S epoxy lining system. The Series 434/435 Perma-Shield H2S epoxy lining system has over a 20-year track record of protecting concrete infrastructure from severe wastewater environments. The concrete repair and coating work required a three-year warranty, so a single source manufacturer for deep repair materials and epoxy coating was required.
|Photo: Courtesy of Erik Otten, Tnemec Company, Inc.
Constructed in early 1970s, this cast-in-place Portland cement concrete structure was experiencing attack section loss from years of exposure to biogenic sulfide corrosion—a type of corrosion that commonly occurs in wastewater infrastructure.
Concrete & Masonry Restoration, Inc. (CMR) was awarded the contract for the concrete repair and epoxy coating work. CMR performed the specified surface preparation using high-pressure water jetting to remove all unsound concrete and to achieve surface cleanliness, to remove corrosion from the existing reinforcing steel and appurtenances, and to provide the necessary anchor surface profile for the Series 217 MortarCrete. CMR installed new steel reinforcement where existing reinforcement had greater than 25% loss of cross section from corrosion. Surface pH testing and surface anchor profile evaluations were performed to confirm compliance with the contract specification.
Following surface preparation and steel reinforcement replacement, CMR applied over 855 cubic feet (approx. 32 cubic yards) of Series 217 MortarCrete using low-pressure grout spray equipment to the overhead, vertical and horizontal surfaces. CMR’s skilled workmanship and application techniques allowed the Series 217 MortarCrete to be applied vertically and overhead in thicknesses exceeding 6-8 inches in a single application lift. Piano wire (also known as ground wires) was stretched along the face of the overhead surfaces and vertical walls so that the Series 217 was screeded to ensure surface build-back to original plane and thickness. After installation and curing of the Series 217, CMR performed additional surface preparation of the Series 217 cementitious repairs to receive the Series 218 MortarClad epoxy cementitious resurfacer.
Badger Specialty Coatings & Construction was subcontracted to install the Tnemec Series 434/435 Perma-Shield H2S epoxy lining. This two-coat system included trowel application of Series 434 Perma-Shield H2S at 125 mils dry film thickness (DFT) followed by a 15-20 mils roller-applied glaze coat of Series 435 Perma-Glaze. After a 72-hour cure, the Tnemec Series 434/435 Perma-Shield H2S epoxy lining was high-voltage holiday tested in accordance with NACE SP0188. A few holidays were identified, repaired, and retested to ensure a pinhole free application of the Series 434/435 Perma-Shield H2S epoxy lining system.
|Photo: Courtesy of Adam Stec, Baxter & Woodman
Following surface preparation and steel reinforcement replacement, CMR applied over 855 cubic feet (approx. 32 cubic yards) of Series 217 MortarCrete using low-pressure grout spray equipment to the overhead, vertical and horizontal surfaces.
The project had its particular challenges. First, the structure was two stories below grade with limited, confined space entry access to the wet wells and screening channel. Second, one of the wet wells was completed while the second wet well and screening channel above the work area remained in-service. Third, most of the 6-8-inch concrete repair work was overhead. CMR, an experienced shotcrete applicator, was able to successfully layer the Series 217 MortarCrete in a wet-on-wet application using low-pressure grout spray, while scrubbing and screeding the product into place. This, combined with the inherent low rebound properties of Series 217, allowed CMR to perform repairs in a single lift.
Lastly, prior to completing the second wet well and screening channel, CMR had to demobilize to work around the wet season and allow the Pumping Station PS-5 to remain online; CMR returned a few months later to complete the project. Also, plugging and bypassing was required to complete the second wet well and screening channel. Plugging was difficult due to excessive corrosion of the 48-inch influent sewer concrete pipe interceptor and a larger size plug had to be installed.
Project MVP Award
Coatings Consultant Erik Otten from Tnemec Company, Inc. specializes in water, wastewater and water storage tank projects. He estimates he’s averaged 50-plus water tank projects a year over the past 15 years in the business.
As for his strong communication skills and knowledge of proper mix ratios which are so critical to his work today, Erik credits those attributes to a job he held earlier in his career: bartending.
EDITOR’S NOTE: While some nominees ran unopposed in 2022, all were deemed worthy of their respective honors by JPCL editors. It is the Journal’s policy to present an award only if the entry meets our established standards. Thank you to those who submitted an exceptional group of nominees.