Polyurea Coatings in Secondary Containment with National Technical Approval. Jürgen Magner Kiwa Polymer Institut Flörsheim / Germany

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1 Polyurea Coatings in Secondary Containment with National Technical Approval Jürgen Magner Kiwa Polymer Institut Flörsheim / Germany

2 concrete substrate high rack tanks organic coating secondary containment = protection in case of accidents

3 Germany water balance law principle of concern for any kind of possible ground water pollution principle of best possible protection for the soil ground water

4 Secondary containment based on concrete Design with reinforcement and maximal crack width of the concrete of 0,2 mm If possible: no joints Concrete is not dense and allows the passage of ground water / soil contaminating liquids

0,2 mm If possible: no joints Concrete is not dense and

5 Requirement for organic coatings Crack bridging (> 0,2 mm) Adhesion Resistance to external exposure (freeze, UV) Chemical resistance Electrostatical discharge behaviour

6 No existing national norm No European Norm No European Technical Approval Guideline

7 National approval guidelines for sumps, secondary containment and concrete surfaces in facilities for the storage, filling and handling of water polluting liquids, Zulassungsgrundsätze für Auffangwannen, Auffangräume und Flächen aus Beton in Anlagen zum Lagern, Abfüllen und Umschlagen von wassergefährdenden Flüssigkeiten Issuer: DIBT- German Institute for Construction Technique Deutsches Institut für Bautechnik

Auffangräume und Flächen aus Beton in Anlagen zum Lagern, Abfüllen und Umschlagen von

9 Successful story since the middle of the 80s More than 350 approvals Chemical resistance test procedure and list of more than 15 main chemical classes has even lead to EN 13529

10 Chemical resistance

11 EN Products and systems for the protection and repair of concrete structures - Test methods - Resistance to severe chemical attack Liquid class 1-3

12 Liquid class 4

13 Liquid class 5-8

14 Liquid class 9-12

15 Liquid class 13-15

16 Supplementary liquids or higher concentrations not systematically included in the list have to be tested separately Example Class 10: sulfuric acid of 20 % Included: hydrochloric acid of up to 20% Not included: HCl conc.

separately Example Class 10: sulfuric acid of 20 %

17 Test device for testing of chemical resistance Key: 1 Fixing plate 2 Compressed air hose 3 Glued rings 4 Concrete slab 5 Chamber 6 Testing liquid 7 Organic coating system 8 Metal frame

23 Levels and exposures acc. to containment character

24 Inspection after Exposure Blistering Flaking Cracking Optical changes (colour gloss) Adhesion, Hardness Penetration of chemicals

25 Chemical class Level for a polyurea system 1 MIDDLE L2 4 MIDDLE L2 5a MIDDLE L2 6 LOW LAU1 6b LOW LAU1 7 LOW LAU1 8a MIDDLE AU2 9 HIGH AU3 9a LOW LAU1 10 HIGH AU3 11 HIGH AU3 13 HIGH L3 14 HIGH AU3 15 LOW LAU1 Results for Polyurea

26 Crack bridging

27 Coating system Crack bridging principle via static bending test > 0,2 mm

28 Crack bridging test device

29 3-point bending test with electronic elongation gauge

30 Test specimen with failure

31 Results for Polyurea Outstanding performances in all cases > 2mm Coating over joints = monolithic protection

32 outdoor exposure (6 and 24 months)

33 ou

34 indoor exposure (6 and 24 months)

35 indoor exposure vertically in wet surroundings (storage in boxes with wet sand)

36 Results for Polyurea no degradation no cracks no signal for ageing

37 wear resistance

38 Test device acc. to EN Methods of test for screed materials Part 4: determination of wear resistance

40 Trafficability with BCA tester following EN for movers - forklifters procedure adapted for technical approvals 1 cycle: 2850 revolutions for vulcolan tyres: 2 cycles for polyamid tyres: 10 cycles

41 Results for Polyurea no trace of wear

42 Electrostatical discharge (in case of inflammable liquids) a) with electrostatic discharging top sealer b) with additives

44 Results for Polyurea Formulation with additives and top sealer without any electrostatical discharging problems

45 occurring problems Blistering by renunciation of primer

46 occurring problems Adhesion loss without primer

47 Executed jobs

59 Spray application on geotextile

61 Spray application on concrete retainment basin wall

63 Panel with system description

66 Test of electrical surface resistance

67 Conclusion Polyurea based coating systems are able to fulfill all criterias for ground water protection in industrial secondary containment according to German approval guidelines Lower chemical resistances in comparison with e.g. the typical range of epoxies compete with a much higher range of crack bridging capabilities, even with their performance to bridge joints

68 Conclusion Depending of the location (verticals, steric hindrance) polyurea profit of their ease of application, e.g. lower number of working steps, higher range of thickness applicability per step These added values can be worth higher system costs

69 Thanks for your attention and patience Let s have a break!

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