When choosing a secondary containment system it must be chosen based on its ability to withstand long term contact with the natural elements (weather), whatever the tanks hold (unrefined oil, fuels, acids, etc..). It must have excellent puncture resistance, resistance to UV degradation and withstand the thermal and/or chemical expansions and contractions; as well as insuring compliance with the local, state and federal laws. Current local, state and federal legislation have raised the requirements (and fines) for facility owners that contaminate the environment. Once a catastrophic failure has occurred, your Secondary Containment System immediately becomes your Primary Containment. It s worth repeating that, when it s necessary to rely on secondary containment, it becomes primary containment. All Tech Industries (ATI) offers a new government approved Secondary Containment Solution that has features no other Containment Solution can offer. HDPE is one of the oldest containment solutions still available to Oil & Gas Operators. The issue is it offers the Operator old and out dated performances which are no longer acceptable to most Agencies. However, HDPE is comfortable to operators. Like an old pair of work boots. Although, sooner or later, everything is either retired or replaced with new technology. This document contains a list of the performances of HDPE (or like there of) compared to All Tech Industries government approved replacement (Ultra COAT Secondary Containment Solution).
MANUFACTURING THICKNESS TOLERANCE: HDPE: A mil, as used to describe a geomembrane, is defined as 1/1000 th of an inch (0.001 inch). The methods of measurement of the thickness of ATI s Ultra Coat and textured HDPE differ significantly. In order to fully understand this difference, read ASTM D 5199 for smooth geomembranes and ASTM D 5994 for textured geomembranes. HDPE is manufactured to a thickness tolerance of +/ 10% which is measured using minimum average roll value (MARV) methods. This means the minimum thickness of 60 mil textured HDPE should not be less than 54 mils (specification thickness of 0.060 inches, minus 10% 0.006 inches = 0.054 inches) in 8 out of 10 measurements across the roll width. It should be noted that since minimum average roll value is used in calculating the thickness of the HDPE material, it is considered adequate for a thickness measurement of 51 mils ( 15%) to be accepted for one or two of the measurements, as long as the minimum average of the measurements is above 0.054 inches. Ultra COAT: ATI utilizes digital recordings of each Technician s performance including historical data of Temperature, PSI, Spray Product Usage, Rate of Work, Time of work, etc. This real time data is monitored every 0.000001 of a second for consistency and accuracy (no tolerances) and is configured to record a snap shot every 10 seconds in an electronic database. This information (data) provides Detailed Reporting per project and can be accessed through ATI s Customer Web Portal. TENSILE STRENGTH: HDPE: Tensile strength at break for 60 mil textured HDPE is 90 lbs/in (1500 psi). HDPE is tested at a speed of 2 inches per minute. Ultra COAT: ATI s Ultra COAT solution features an amazing Tensile Strength (ASTM D 412) of 4,219 psi (23.3 mpa). Three times the tensile strength of the typical 60 mil HDPE. * Hit or cut a sample of Ultra COAT and Hit or cut (tensile stress) a sample of HDPE. Ultra COAT provides great protection to withstand the impact of cuts and gouges (commonly found from equipment/machines/tools). ELONGATION at BREAK: HDPE: The minimum elongation at break for 60 mil textured HDPE geomembrane is only 100%. Polyethylene proponents may quickly point out that SMOOTH HDPE has a minimum elongation at break of 700%... but remember, smooth HDPE is NEVER used on a slope (slip resistance), and so the value is not relevant in the comparison of geomembranes in actual use. Ultra COAT: The minimum elongation at break for ATI s Ultra COAT (standard base line, can be specialty ordered higher) features an elongation of 1,014.8%. Ten times the elongation of the typical 60 mil HDPE. Ultra COAT materials provide excellent performance in immersion service while being more versatile than conventional sheet systems. These 100% spray applied solid abrasion resistant membranes have an excellent adhesion and a low perm rating that prevents degradation of the substrate from harsh chemicals or water. Unlike other options, like the HDPE.
FAILURE at YIELD ELONGATION: HDPE: The minimum yield elongation for 60 mil textured HDPE is 12% (GRI GM 13). This is the point at which the HDPE fails. HDPE is also elastic, but only through elongation up to its yield point, at about 12%. Then the material becomes plastic. When the yield point is exceeded, HDPE is no longer the same material. It is no longer elastic and changes to a plastic state. Once the HDPE material has elongated beyond the 12% yield point, it can no longer function as a geomembrane. Ultra COAT: Ultra COAT is exceptionally tough (4,219 psi tensile) and flexible (elongation 1,014.8%) to resist thermal stresses to compensate for substrate cracking or movement and provide impact resistance. These membranes are spray applied coatings that eliminate all seams regardless of the size of the liner, even in low temperatures. These membranes are ideal for protection of metal, steel, polyurethane foams and concrete containment structures or used for geotextile applications, offering a UV stable and chemical resistant membrane. The 100% solid, VOC free and rapid cured products follow any contour and provide a monolithic containment barrier. Where colorfastness is critical, factory added pigments and dyes can be added to achieve critical color(s) matching. STRESS CRACKING: HDPE: Stress cracking of HDPE can be compared to the cracking of an automobile windshield. A windshield is installed with a neoprene or rubber gasket around the perimeter to isolate it from the vehicles metal frame, and cushion it from being twisted or subjected to unequal stresses. A minuscule stone chip or tiny scratch is all it takes to initiate a crack in a windshield when a small amount of stress is applied (a bump at the car wash, a sudden change in temperature ). Crystalline plastics like HDPE behave in much the same way. HDPE geomembrane must not be subjected to unequal stresses in order to minimize stress cracking. Polyethylene manufacturers test their material for environmental stress cracking. However it is interesting to read the footnotes. For instance, one typical note: NCTL for HD Textured is conducted on representative smooth membrane samples. This means stress crack testing is likely never actually performed on textured 60 mil HDPE. Ultra COAT: ATI s Ultra COAT can withstand the everyday stresses of oilfield operations. When you cut an Ultra COAT sample with a sharp knife, the cut nearly disappears. When you cut HDPE or Stress Crack it, it s very easy to find the cut! Ultra COAT stands up to the hardest use.
OXIDATION: HDPE: In order to thermally join textured 60 mil HDPE panels for repairs it is necessary to remove the surface oxidation from each of the polyethylene sheets before extrusion welding. This process is done using hand held electric grinders using heavy grit sanding disks. Welding specifications limit the amount of surface grinding to a maximum of 10% of the sheet thickness (6 mils in the case of 60 mil textured HDPE). (For comparison, 5 mils is the thickness of a sheet of stationary paper). This means a technician with a hand grinder operating at 1,200 rpm using 80 or 100 grit sanding disks is limited to a tolerance of 0.006 inches when grinding the surface of a 51 mil thick textured HDPE liner. (51 mils is the minimum thickness to still be called 60 mil textured HDPE). Considering he never exceeds (?) the 0.006 limit, at the point of each repair weld on a 60 mil textured HDPE liner, the material can be 45 mils thick and still qualify as 60 mils. This is a reduction in thickness of 15 mils, a full 25% of the original thickness. Ultra COAT: ATI s Ultra Coat is 100% UV Resistant and 100% Seamless. Our spray applied containment solutions eliminate the maintenance costs associated with other liner systems. Ultra COAT has the refined, consistent grain surface that looks great, as if it came from a factory. Unlimited thickness...non skid protection that looks great as well! Non Skid has been called the cottage cheese look due to its rough appearance. Plus, because Ultra COAT dries instantly (3 to 5 seconds) it s very easy to get coverage on vertical surfaces. FLEXIBILITY: HDPE: Textured 60 mil HDPE requires management of waves and wrinkles during installation to prevent any folds in the material. Folds and wrinkles are not allowed ever in textured 60 mil HDPE. Folds in textured HDPE will cause stress cracking in the material. Forensic analysis has also shown that buried waves in HDPE are likely to remain in place throughout the life of the installation and can serve as conduits for liquid flow above or below an HDPE geomembrane. Ultra COAT: ATI s spray applied Ultra COAT molds precisely to the contour of the topography. Wrinkles and waves are a non issue. As the product is applied using spray applied heated plural component high pressure specialized equipment that incorporates a high pressure impingement type mixing. Sealant and Coating systems can be combined with an engineering fabric for support and 100 percent solids spray applied sealant or coating containment system to form a state of the art flexible chemical resistant and tough containment membrane. Installation of these systems is fast and easy due to their rapid cure time (30 seconds) and insensitivity to most environmental conditions.
PRODUCT PERFORMANCE RECAP: HDPE Ultra COAT Tolerance +/ 10% monitored every 0.000001 of a second Tensile Strength 60 mil is 90 lbs 60 mil is 4,219 lbs Elongation at Break 60 mil is 100% 60 mil is 1,014.8% (ten times HDPE) Failure at Yield Elongation 60 mil textured HDPE is 12% (GRI GM 13) 60 mil textured Ultra COAT is 1,014.8% (ASTM D 412) Stress Cracking Yes Critical Factor No Zero Factor Oxidation Flexibility Yes A reduction in thickness of 15 mils, a full 25% of the original thickness Textured 60 mil HDPE requires management of waves and wrinkles during installation to prevent any folds in the material. WARRANTY UNKNOWN 20 YEARS No A zero reduction in thickness or color performance. Zero factor or concerns of waves, folds, or wrinkles during installation. No concern AFTER installation is completed. *Please note this is a baseline. It is provided only as a starting point. Physical properties of All Tech Industries Ultra COAT can be adjusted to meet specific application requirements. For a more detailed discussion on the advantages and benefits of Ultra COAT or the other solutions we offer, please contact an ATI engineer at (432) 897 1533 or (989) 826 9999 or Info@AllTechIndustries.com We do not know of another solution available in the marketplace that can sustain the extreme environments (heat, cold, wind, rain, snow, ice, movement, etc...) or the physical rigors imposed by personnel and machines/equipment like the ATI applied Ultra COAT Secondary Containment Solution. This is why we are the only company in the industry that offers a 20 Year Warranty included in the Purchase Price of the Solution. Call Today to Schedule an Appointment and Learn How We Can Assist You. All Tech Industries (432) 897 1533 Office info@alltechindustries.com www.alltechindustries.com