Municipal Wastewater

Manholes

Project: FY 13/14 Manhole Rehabilitation & Replacement Project
Location: Long Beach, CA
Owner: Long Beach Water Department
Engineer: Long Beach Water Department / Engineering
Applicator: Ayala Engineering, Anaheim, CA
Sauereisen Representative:
Mike Keating, J.A.CRAWFORD CO.
Products:

• 210X – SewerGard High Strength

Method of Application:

• Graco Xtreme 60 Spray Pump

Environment / Exposure:

• Municipal Wastewater

Project Details:

• Project includes the rehabilitation of 23 existing brick sewer manholes with cementitous underlayment and SewerGard No. 210X at 125 mils. The manholes were rehabilitated while in service.
• Previous city specifications called out rehabilitation and coating with polyurethane lining. Continuous failures of polyurethane linings lead to conversion to SewerGard No. 210 epoxy lining.

Manholes

Project: Amity Township Manholes
Location: Amity Township, PA
Owner: Amity Township Board of Supervisors
Engineer: ARRO Consulting
Applicator: SWERP, Inc.
Sauereisen Representative:
Corrosion Technology Systems
www.corrosion-tech.com
Products:

• F-121 – Substrate Resurfacer
• 210RS – SewerGard Rotary Spray

Method of Application:

• Spray applied cementitious resurfacer and epoxy topcoat.

Environment / Exposure:

• Municipal wastewater

Project Details:

• Restoration of six deteriorated force main discharge manholes from the affects of hydrogen sulfide induced corrosion.
• Restoration included resurfacing using the F-121 SubstrateReSurfacer that was spray-applied via a rotary-spray system
• Corrosion protection using Sauereisen’s No. 210RS SewerGard epoxy lining system applied at 1/8” to protect the resurfaced manholes from future microbiologically induced corrosion.

Manholes

Project: Brookeline Manhole Rehab
Location: Brookeline, MA
Owner: Town of Brookline
Engineer: BETA Group, Inc.
Applicator: National Water Main Cleaning Co.
Sauereisen Representative:
KDS Corrosion Solutions
Products:

• F-180 Instaplug Hydraulic Cement to stop active leaks
• F-170 Fast Set for deep patching
• 210XHB Sewergard Epoxy corrosion and water barrier

Methods of Application:

• Hand application of F-180 to stop active water leaks
• Minor and deep patching by hand with F-170 Fast Set
• Plural component spray application of 210XHB up to 250 mils in a single coat

Environment / Exposure:

• Over 250 municipal wastewater manholes in densely populated area, with significant water infiltration and high levels of hydrogen sulfide gases
• Variety of original construction methods of the manholes; brick, concrete block and precast concrete, had to be addressed

Project Details:

• Specifications called for 250 mils of 100% solids epoxy with no cementitious underlayment
• Sauereisen’s 210XHB SewerGard epoxy met or exceeded all specification requirements
• The 210XHB was applied up to 250 mils in a single coat with each manhole completed in a single application

Manholes

Project: City of Buena Park – Sewer Manhole Lining and Rehabilitation Project
Location: Buena Park, CA
Owner: City of Buena Park
Engineer: City of Buena Park Public Works Engineering
Applicator: Ayala Engineering, Anaheim, CA
Sauereisen Representative:
Mike Keating, J. A. CRAWFORD CO.
Products:

• SewerGard No. 210X @ 125 mils

Method of Application:   Graco Xtreme 70 pump
Environment / Exposure:  Existing municipal collection system sewer with moderate to severe corrosion.
Project Details:

• Each year the City of Buena Park, CA solicits bids for sewer manhole rehabilitation and coating. For project year 2012/2013 the quantity of manholes was established as 150 each.  The manholes are typical 3’ diameter and range in depth from 4’ to 29’ deep.  The City has traditionally only specified polyurethane linings (Sancon and Zebron brands) but after multiple application failures consideration was given to epoxy alternatives. SewerGard No. 210X was presented to the City Engineering Department as an acceptable alternative. Key consideration was given to the Public Works “Green Book” and since SewerGard No. 210 meets the strict requirements of this qualification it was approved and added to the specification.  Ayala Engineering then successfully bid the project.

Manholes

Project: Abalone Cove Sewer Manhole Rehabilitation Project FY 16/17
Location: Rancho Palos Verdes, CA
Owner: City of Rancho Palos Verdes
Applicator: Ayala Engineering, Anaheim, CA
Sauereisen Representative:
Mike Keating, J. A. CRAWFORD CO.
Products:  SewerGard 210X @ 125 mils
Method of Application:   Graco Xtreme 70 pump
Environment / Exposure:
Existing municipal collection system sewer with moderate to severe corrosion.
Project Details:

• In the City of Rancho Palos Verdes, the team at Ayala Engineering underwent the process of rehabilitating seventy (70) existing sewer manholes and applying a corrosion resistant, 100% solids epoxy lining. The rehabilitation was done via abrasive blasting, power-washing and the eventual use of a cementitious underlayment to rebuild a consistent and sound substrate. Then, using a Graco Xtreme 70 airless spray pump, the workers at Ayala Engineering used the SewerGard 210X lining to build a corrosion resistant barrier at 125 mils thickness.

Manholes

Project: Pima County Manhole Rehab
Location: Tucson, AZ
Owner: Pima County Wastewater Management
Engineer: In-house
Applicator: Optco – Apache Junction, AZ
Sauereisen Representative:
Roger Bird, RNS Distributing, Inc.
Products:

• F-121 Substrate Resurfacer
• 210T SewerGard

Method of Application:
Trowel
Environment / Exposure:
Ultra high hydrogen sulfide/sulfuric acid environment with elevated temperatures exceeding 110^oF.
Project Details:

• Preparation consisted of Water Blasting with 5000-psi to remove all weak and chemically-attacked concrete.

• Substrate Resurfacer No. F-121 was applied ¼” thick to restore chemically attacked concrete.
• SewerGard No. 210 Epoxy Lining was applied at a thickness of 125-mils.

• High-Voltage Spark Testing was performed to identify any pinholes.

After many years of service the structure is still in excellent condition

Grit Chambers

Project: Grit Pit Channels at a WWTP
Location: El Tuque Ward, Ponce, Puerto Rico
Owner: Puerto Rico Aqueduct and Sewer Authority (PRASA)
Engineer: Eng. D. Cancel, Eng. D. Velazquez, Eng. J. Velez
Applicator: Pipeliners of Puerto Rico, Inc.
Sauereisen Representative:
Harold Vargas Torres, Carribe Linings
Products:

• 210RS SewerGard
• F-170 SewerSeal
• F-180 InstaPlug

Method of Application:

• Rotary Spray applied at 60-120 mils with a pump and Spincaster nozzle. This was done inside the grit pit and the channels.
• After the No. 210RS was sufficiently cured, a holiday detector was used to ensure a continuous pinhole-free lining.

Environment / Exposure: Aggressive Municipal Wastewater
Project Details:

• In a challenging economy, where budgets are restrictive and revenues are stagnant or declining, PRASA Ponce WWTP face the real and potentially costly problem of infrastructure rehabilitation. Just because the economy is in a slowdown, corrosion is not. The PRASA team is choosing to adjust their capabilities to stay ahead of the corrosion curve and deal with corrosive issues to avoid the higher cost of deterioration and replacement.
• SewerGard is specifically formulated for municipal wastewater environments and offers an economical solution to Microbiologically Induced Corrosion (MIC). SewerGard exhibits moisture tolerance allowing it to bond directly to damp concrete. It also resists high concentrations of sulfuric acid as well as chemicals introduced during the treatment process.

Tunnels

Project: Big Walnut Sanitary Trunk Sewer Extension
Location: Columbus, Ohio
Owner: City of Columbus, Department of Sewerage and
Drainage
Engineer: DLZ – Columbus, Ohio
Contractor: Kassouf/Mole/Murray Hill/Jay Dee – Jt Venture
Applicator: The Kassouf Company
Sauereisen Representative: Wm. Neundorfer Company
Products:

• SewerGard No. 210T
• Epoxy Filler Compound No. 209

Method of Application:

• Trowel applied

Environment / Exposure:

• H₂S + Microbiologically Induced Corrosion

Project Details:

• New Construction – approximately 10,000 sf of SewerGard lining applied at 125 mil and 250 mil thicknesses over poured-in-place concrete.
• Areas of protection included outfall and access structures as well as poured-in-place concrete junction areas connecting drop shafts to tunnel.
• Tunnel diameter: 6’, Maximum depth: 180 ft
• Materials of Construction – Access shafts: aggregate reinforced FRP. Tunnel: precast concrete with HDPE lining.  All poured-in-place concrete: SewerGard 210T lined.  Precast concrete lids: SewerGard 210T lined.  Carbon steel: SewerGard 210G lined.

Tunnels

Project:  Kaneohe-Kailua Sewer Tunnel Project
Owner: City and County of Honolulu
Engineer: Wilson Okamoto Corporation
General Contractor: Hensel Phelps Construction Co.
Coating Contractor: Honolulu Painting Co., Ltd
Sauereisen Representative: J. A Crawford Co.
Products:

• Filler Compound 209
• SewerGard^® Sprayable 210S

Method of Application: Trowel & Airless Spray
Environment / Exposure:
Microbiologically Induced Corrosion (MIC) and erosion from wastewater with elevated temperatures of Hawaiian climate.
Project Details:
This project was specified with the 209/210S system at 60-mils.  The size and scope, variety of structures, various configurations, terminations, depth of structures, attention to detail, masking, and the smooth finish achieved is very impressive.

Tunnels

Project: Mexico City Central Collector Tunnel
Location: Mexico City
Owner: Mexico City Water System
General Contractor:  ICA, Oegsa, Const. Estrella
Applicator: Enseres Mexicanos, Escaltech, Fagar
Sauereisen Representative:
Luis Ruiz Noguez, Comex-Kroma S.A. de C.V.
Products:

• 210S SewerGard Sprayable
• 210G SewerGard Glaze

Method of Application: Airless Spray
Environment / Exposure:

• Hydrogen Sulfite gas
• Sulfuric Acid
• Carbonic Acid
• Miscellaneous waste acids and solids

Project Details:

• The city was rehabilitating a major trunk sewer and was looking for proven technology that could resist abrasion, hydrogen sulfide and aggressive wastewater.
• Over 200,000 square feet were lined with Sauereisen’s 210S.
• Upon first inspection, the material has performed phenomenally.
• Sauereisen was chosen because of its product history with 1,000’s of applications across the globe and superior local and corporate technical support.
• Tunnel was repaired and lined in record time, saving the city substantial funds.

Digesters

Project: Camden County MUA Digester Rehab – Walls in 4 Anaerobic Digester tanks
Location: Camden, NJ
Owner: Camden County
Engineer: Dvirka & Bartilucci
Applicator: Zack Painting, Inc.
Sauereisen Representative:
Corrosion Technology Systems, Inc. www.corrosion-tech.com
Products:

• F-121 Substrate Resurfacer
• 210XHB SewerGard Epoxy

Method of Application:

• F-121: Wet shotcrete method with trowel and broom finish
• 210XHB via heated plural component spray

Environment / Exposure:
Municipal Wastewater
Project Details:

• 30 plus year old digesters (4) with deteriorated original coating system resulting in MIC attack with up to ½” of concrete substrate loss
• 40,000 psi ultra-high pressure water jetting resulted in a clean, solid substrate with a CSP of 6 and up and a surface pH exceeding 9
• F-121 Resurfacer applied at a minimum of ½” to provide uniform substrate
• 210XHB applied at 125 mils to provide complete corrosion protection, with a smooth cleanable surface

Digesters

Project: Derry Borough Digesters
Location: Derry Borough, PA
Owner:  Derry Borough, PA
Applicator: Betler Construction
Sauereisen Representative:
Tom Kust, Kust Industrial Products
Products:

• F-121 – Substrate Resurfacer
• 210X – SewerGard High Strength
• F-370 HydroActive Grout

Method of Application:

• Spray, Trowel, Pump

Environment / Exposure:

• Hydrogen Sulfide

Project Details:

• Two in-ground concrete digesters 39’x24’x10′
• Approximately 75 years old
• Severely cracked
• F-370 injected to seal leaking cracks
• F-121 applied to resurface substrate
• 210X was sprayed to provide corrosion resistance – 100 mils at the top 4 ft. (fume line) and 80 mils throughout the remainder of the tank.

Digesters

Project: Hermitage Digesters
Location: Hermitage, PA
Owner: Hermitage Municipal Authority
Engineer: Herbert, Roland & Grubic
Applicator: Baker Painting & Coating
Sauereisen Representative:
Tom Kust, Kust Industrial Products
Products:

• 210X – SewerGard High Strength
• 209 – Filler Compound

Method of Application:

• Screed / Spray

Environment / Exposure:

• Wastewater / Hydrogen Sulfide

Project Details:

• Two Twenty-year-old 40′ diameter X 25′ high concrete digesters were high pressure water blasted.

• The remaining voids were filled with No. 209 Filler Compound and a spray application of No. 210X SewerGard High Strength was applied at 80 mils in thickness.

• High Strength & abrasion resistance were the primary drivers in maximizing service life.

Digesters

Project Name:  Honouliuli WWTP – New Solids Handling
Facility Project – Anaerobic Digester Lining
Location: Ewa Beach, Hawaii
Owner:  City and County of Honolulu
Applicator: The Zelinsky Company – Kapolei, Hawaii
Sauereisen Representative:
Mike Keating, J. A. CRAWFORD CO.
Products:

• 209 Filler Compound
• 210S SewerGard

Method of Application:

• Trowel application of No. 209
• Spray application of No. 210S

Environment / Exposure:
Project involved the coating of new anaerobic digesters, which provide an environment where anaerobic bacteria (bacteria that can not live with oxygen present) are able to thrive and can break down the organics in sludge into stable compounds. Anaerobic digestion reduces solids, odors, and pathogens, and it conditions sludge so it dewaters rapidly. Methane gas, produced as a byproduct of this process, is used for mixing the digesters.
Project Details:

• The J.A. Crawford Company was instrumental in developing the specification and working with the contractor to secure this project.
• The applicator, The Zelinsky Company utilized Graco’s new 70:1 and 90:1 ratio pumps on this project. Both showed improved application of No. 210S when compared to the older 45:1 and 56:1 models.  Pete Jansen provided on-site Tech Service to re-familiarize the contractor with No. 210S.
• The three concrete digester tanks encompassed more than 50,000 square feet of surface area.

Digesters

Project: Lambertville Digester Project
Location: Lambertville, NJ
Owner: Lambertville Municipal Utilities Authority
Engineer: CDM Smith
Applicator: BMS Construction Services
Sauereisen Representative:
Corrosion Technology Systems, Inc.
www.corrosion-tech.com
Products:

• 210X -SewerGard High Strength
• F-180 InstaPlug & No. 209-HB Compound Filler
• 501 – ConoWeld

Method of Application:

• Spray applied with conventional airless spray equipment

Environment / Exposure:

• Municipal wastewater

Project Details:

• This 4,400 ft² digester was built in 1957. After cleaning and surface preparation were completed, numerous large cracks, many of them leaking heavily from the adjacent in-service structures, were discovered throughout the tank.  A very good profile with exposed aggregate remained.
• The leaking water was first stopped with the F-180. Then cracks were repaired using the No. 501 primer with cabosil and fiberglass cloth for reinforcing.
• Resurfacing over the entire surface involved a scratch coat of No. 501 primer with cabosil to increase it’s thickness.
• Corrosion protection was achieved with a spray applied No. 210X SewerGard 100% solids epoxy at a total thickness of 125 mils.

Wet Wells

Project: Kenwood Pump Station Wet Well
Location: Levittown, PA
Owner: Lower Bucks County Joint Municipal Authority
Engineer: D&B / Guarino Engineers, LLC
Applicator: Aulffo Painting
Sauereisen Representative:
Corrosion Technology Systems
www.corrosion-tech.com
Products:

• F-120 -Castable Underlayment
• 210G – SewerGard Glaze

Method of Application:

• Hand applied cementitious underlayment and spray applied epoxy lining via standard airless spray equipment.

Environment / Exposure:

• Municipal wastewater

Project Details:

• Refurbishment of a concrete pump station wet well to repair the heavily deteriorated floor and discharge channel.
• Restoration included casting new flow channels utilizing Sauereisen’s F-120 Castable cementitious underlayment.
• Corrosion protection from the affects of microbiologically induced corrosion by applying two coats of the No. 210G SewerGard Glaze epoxy lining system at a total thickness 60-mils for a pin-hole free system.

Wet Wells

Project: Mifflinburg 8^th St. Pump Station Wet Well
Location: Mifflinburg, PA
Owner: Borough of Mifflinburg
Engineer: Herbert, Rowland and Grubick
Applicator: Wenrich Painting
Sauereisen Representative:
Corrosion Technology Systems
www.corrosion-tech.com
Products:

• 501 – ConoWeld
• 210S – SewerGard Sprayable
• 210G – SewerGard Glaze

Method of Application:

• Spray applied with conventional airless spray equipment

Environment / Exposure:

• Municipal wastewater

Project Details:

• Restoration of 6’ diameter x 17’ deep steel pump station wet well.
• Surface preparation included abrasive blasting the steel substrate to remove any surface rust and to provide a profile for the material to mechanically bond to.
• After priming with the No. 501 ConoWeld, the entire wet-well was lined with Sauereisen’s No. 210S fiber reinforced SewerGard at 60-mils.
• To ensure a pin-hole free application, a 20-mils topcoat of the No. 210G SewerGard epoxy glaze was spray applied over the entire surface.

Wet Wells

Project: CCMUA Delaware No. 1 WPCF Influent Structure Rehabilitation
Location: Camden, NJ
Owner: Camden County Municipal Utilities Authority
Engineer: D&B / Guarino Engineers, LLC
Applicator: TT&T Finishing Contractors
Sauereisen Representative:
Corrosion Technology Systems, Inc.
www.corrosion-tech.com
Products:

• F-121 RestoKrete Substrate ReSurfacer
• 210X SewerGard
• 210FS SewerGard Fast Set

Method of Application:

• F-121 via Rotor Stator Pump
• 210X via Conventional Airless Spray

Environment / Exposure:

• Municipal Sewage

Project Details:

• Rehabilitation of 30,000+ ft² of badly deteriorated concrete influent structures to restore structural integrity and to provide long term corrosion protection.
• The project involved high pressure water blasting the substrate to remove sewage and loose, damaged concrete.
• After sound concrete was obtained, Sauereisen’s F-121 was spray-applied and troweled to smooth and rebuild the surface. In areas greater than 1” thick, steel wire reinforcing was installed.
• Sauereisen No. 210X was spray applied via conventional airless spray equipment in two 70-mil coats totaling 140-mils.
• Sauereisen No. 210FS was utilized in areas requiring a quick cure of the SewerGard epoxy.

Headworks

Project:  Water Pollution Control Facility – Electrical and Headworks Bypass Improvements
Owner: City of Las Vegas, NV
Engineer: CH2M Hill, Las Vegas, NV
General Contractor: McCarthy
Construction Manager: Carollo Engineers
Coating Contractor: Southwest Specialty Coatings, Inc.
Sauereisen Representative: Mike Keating, J. A. Crawford, Co.
Products:

• ConoPrime 500 @ 8 mils
• Filler Compound 209 to fill voids and irregularities
• SewerGard Sprayable 210S @ 90 mils (tan)
• SewerGard Glaze 210GL @ 20 mils (gray)

Method of Application:
roller applied primer, hand trowel applied filler compound and spray applied SewerGard
Environment / Exposure:
Hydrogen Sulfide gases common to municipally waste environment.
Project Details:

• Surface preparation and coating of new construction wastewater bypass infrastructure (approximately 20,000 sq. ft.) by application of Sauereisen Filler Compound 209 to fill voids and irregularities, SewerGard 210S Lining at 90 mils thickness for corrosion protection and SewerGard Glaze 210G (contrasting gray color) at 20 mils thickness for additional protection and identifying “wear” coat.

• Very large scale, new construction project at City of Las Vegas Water Pollution Control Facility implementing new technology that required the construction of a new headworks and by-pass diversion channel. All concrete areas exposed to hydrogen sulfide gas was specified to be lined with Sauereisen SewerGard 210 System; primer, filler compound, corrosion coating and glaze coating (in contrasting color to identify wear and tear).

Headworks

Project:  Headworks Rehabilitation Project
Location:  Laughlin Water Reclamation Facility, Laughlin, NV
Owner: Clark County Water Reclamation District (CCWRD)
Engineer: Stanley Consultants, Las Vegas, NV
Applicator: RPI Coating (now Southwest Specialty Coatings)
Sauereisen Representative:
Mike Keating, J. A. CRAWFORD CO.
Products:

• Resurfacing Compound No. F-121
• SewerGard No. 210S

Environment / Exposure: Municipal Wastewater
Project Details:
Rehabilitation and coating of existing Headworks by application of Sauereisen Resurfacer No. F-121 and Sauereisen SewerGard No. 210 Lining.  Existing surfaces were severely corroded with rebar exposure.  After surface preparation No. F-121 was applied over the entire surface area and then SewerGard No. 210S was spray applied at 125 mils thickness (two coats).

Clarifiers

Project: Clark County Water Reclamation District Primary Clarifiers 13 & 14 Project
Location: Las Vegas, NV
Owner: Clark County Water Reclamation District – Main Treatment Plant
Engineer: Black & Veatch Corp.
General Contractor:  MMC Contracting Corp.
Applicator: Bryan Painting and Decorating
Sauereisen Representative:
Mike Keating, J. A. CRAWFORD CO.
Products:

• 209HB Filler Compound
• 210S SewerGard Sprayable

Method of Application:

• Rounded steel trowel – No. 209HB
• Graco 70:1 Xtreme – No. 210S

Environment / Exposure:

• Very high level of H2S exposure
• Aggregate exposure exceeded 2” in several areas

Project Details:

• 75,000 ft² of concrete surface area to be rehabilitated and/or coated
• Surface Preparation by combination of hydro/abrasive blasting due to dust concern of area residence
• Difficult application conditions with day time ambient temperatures @ 110^oF and night time @ 85^oF
• Nighttime application – declining ambient temperatures
• Pull test per ASTM D4541 – exceeded 400 psi

Clarifiers

Project: Six (6) Rehabilitated clarifiers
Location: Sand Island WWTP – Honolulu, Hawaii
Owner: City and County of Honolulu
Applicator: Zelinsky Company
Sauereisen Representative:
J.A. CRAWFORD CO.
Products:

• Urethane Filler Compound 309
• ConoPrime 502
• ConoFlex 381
• ConoThane Glaze 310
• SewerGard Glaze 210

Method of Application:  Trowel & Airless Spray
Environment / Exposure:
Microbiologically induced corrosion and erosion from wastewater with elevated temperatures of Hawaiian climate.
Project Details:

• 309 was applied on all walls to fill voids, irregularities, and air pockets in the concrete. The filler compound provided a uniform surface for the application of 502 primer.
• 381 was plural component spray-applied to all walls at approximately 100 mil thickness over the existing corrosion lining.
• 310 Glaze was applied over 381 at approximately 15 mil thickness for additional Corrosion and UV protection.
• 210 Glaze airless spray-applied at approximately 20 mils to floor of clarifier for Corrosion protection and added abrasion resistance.

Clarifiers

Project: Wyandotte Clarifiers
Location: Wyandotte, MI
Owner: Wyandotte Waste Water
Engineer: Hubble Roth & Clark
Applicator: Royal Restoration
Sauereisen Representative:
Tim Flanagan, Flanagan Sales & Associates
Products:

• RestoKrete Filler Compound No. 209
• SewerGard Sprayable No. 210S
• SewerGard High-Strength No. 210X

Method of Application: Trowel & Spray
Environment / Exposure: Typical municipal wastewater conditions
Project Details:

• Four (4) Municipal Wastewater Clarifiers totaling over 32,500 square feet

• Voids & bug holes were patched with Filler Compound No. 209