FRP Lining Solutions for Infrastructure Rehabilitation

When selecting rehabilitation solutions for deteriorated infastructure, fiber-reinforced polymer (FRP) systems have numerous advantages. In particular, FRP solutions, such as Epoxytec’s CPP Series, provides the ease of application that contractors need, the cost savings and minimal downtime that owners desire, and the product dependability, strength, and durability that engineers require. The FRP system—in this case, the Epoxytec CPP Sprayliner product—offers high mechnical strength, as expected with FRP lining. In the case of this privately owned country club located in South Florida, the owner was searching for a cost-effective, durable solution to protect and maintain this 13,000 sq. ft. tank with a 500,000 gallon capacity. Epoxytec’s lining system provided the features all parties were looking for.

chemical resistant coatings

THE PROBLEM

The concrete tank showed signs of severe deterioration, with exposed rebar as a result of H2S damage. The existing coating required removal, and a structural solution to reinforce the concrete was essential. Another crucial element was protection from future damage.

PRODUCTS THAT OUT-PERFORM

Epoxytec manufactures performance coatings that are often utilized as lining systems.  The Epoxytec CPP Series (applied and bonded FRP epoxy) is the technology of choice in structural lining. This series is a proprietary, unique, 100% solids formulation of advanced resins (polymers), typically hybrid or blended epoxies, and a reinforcement package of proprietary fillers. These fillers are an assortment of reinforcement agents, such as fibers (synthetic, organic, and inorganic), ceramics, polymer networks, and other advanced materials. Once cured, they form a reinforcement network.

In combination, this epoxy liner is defined as a hybrid form of FRP. However, unlike traditional fabric-impregnated FRP, the system is applied FRP, bonded epoxy (applied and bonded FRP epoxy) which is first liquified, then pumped and spray-applied direct to concrete (DTC) or direct to metal (DTM). It is highly thixotropic and ultra-high build, and exhibits high mechanical strengths. When cured, this technology delivers impressive flexural strengths and the tensile properties required for structural calculations, enhancement, or reinstatement.

Epoxytec’s CPP Sprayliner FRP System is a two-component moisture-insensitive reinforced epoxy. The product is blended with reinforcing agents and various fibers, making it highly adhesive and with structural properties. It also provides chemical resistance and is a 100% solids. It can be sprayed conveniently from a plural-component heated spray rig. The material can be sprayed with ultra-high build, between 1/16” and 1/4” (62.5–250 mils) per pass. Once cured, this FRP system creates a reinforcement lining with high strength and flexural properties for partially or fully deteriorated structures. CPP Sprayliner is conveniently sold in 10-gallon and 100-gallon kits.

THE APPLICATION

The first and most important step, as with any application, is preparation of the substrate. The surface of this tank was blasted with high-pressure water jetting. The substrate was then resurfaced using Epoxytec’s Mortartec Silicate and Mortartec Ceramico. Next, Epoxytec’s CPP Sprayliner was spray-applied as a top coat. Any seams were filled using Epoxytec’s Uroseal 45V.

FINAL LOOK

This project was completed on time and all parties involved were satisfied with the results. The protection provided by Epoxytec’s proven FRP system will enhance the life of this infrastructure and has brought it back to “like new” condition. Using Epoxytec’s spray-applied FRP system allowed for efficient installation time, while also providing quality, durabilty, and strength for years to come.

PROJECT: South Florida Country Club Concrete Tank Rehabilitation

CONTRACTOR: Exceletech Coating and Applications, LLC

DATE: Spring 2019

PRODUCTS: Epoxytec’s CPP Sprayliner     

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*** MCOR (a brand of Epoxytec) offers FRP options that align with the qualities of CPP Sprayliner. Visit http://www.mcor.net/products/frp-spray/ for more details.