Solid Waste Tipping Floor, Push-Walls – Wheelabrator South Broward – concrete restoration and rehabilitation

Wheelabrator South Broward (a Waste Management company) – Hollywood, Florida, USA
Transfer Station / Tipping Floor, Push-Walls
(performed by an Epoxytec certified applicator)

Many waste management facilities face deteriorating problems surrounding their tipping floor structures. In particular, the transfer station push-walls experience a lot of abuse. These constructed cushions in the tipping hall are typically made of concrete, and are designed to absorb impact and wear as refuse transfers from truck dumps to the pit for processing. Often times, the trash builds and slides against the walls as it is pushed to the refuse pit. The transferring mechanism typically consists of bulldozers, which in turn score and push solid waste onto these concrete walls, hence the name – push-walls.

The level of deterioration seen in the above pictures captures the intensity and incredible force of the scoring nature of highly abrasive and wearing solid waste. Discarded trash items both chemical in nature and often time large (such as refrigerators, sofas, trees, metal components, etc.) are constantly tearing apart and spalling chunks of concrete from the push-walls.

The spalling forces are so extreme that inches of concrete deteriorate and leave critical exposed reinforcing bars (rebar) vulnerable to further accelerated corrosion.

A customized material formulated to combat this problem was created by Epoxytec for Wheelabrator, but before installing the product, surface preparation using Ultra-High Pressure (UHP) waterjetting had to remove all unsound and contaminated concrete per NACE No.6/SSPC SP-12 standards. After which form frames must be installed.

The material utilized was Epoxytec 17G. The material has incredible bond strength with the ability to thin-out at the edges. In addition, the material is organic, based from epoxy provide enough elongation to absorb impact and flex with movement in order to prevent pop-outs.

The Epoxytec 17G was a well-thought solution. It was specifically formulated to combat the wearing forces of the solid waste transfer station push-walls. In addition, because of the degree of concrete loss – the Epoxytec 17G rebuilds as a sealed epoxy slab with 17,800psi of compressive strength to reinforce structurally, and cure with such high density that it truly becomes a brute system to combat the abuses the push-walls experience.

Wood forms had to be lined with plastic as a release agent. Typical release agents and molding waxes would not suffice. Epoxytec 17G‘s adhesive strength to so extreme that it bond through most tradition release agents. This is a testament to its bond strength and surface tolerance/forgiveness.

A great attribute about the 17G is its pot life; with approximately 2 hours of pot life (working time) the job can go at a good pace without the worries of losing a kit after mixing from exotherm (ie – overheating with a quick cure).

The Epoxytec 17G was selected because it’s epoxy-based; and therefore, once cured provides a protective sealed barrier and disallows oxygen and other contaminates to migrate through concrete. Sealing the concrete and disallowing oxygen to the rebar will cease oxidation from further occurring and protect the bars for the future.

After removing the forms, the resulting system is Epoxytec 17G as a repair system, rebuilder, filler, and also a high impact, durable, abrasion and chemical resistant sealed liner.

Using a material like 17G results in the ability of feather-edge bonding without the harm of popping or weakening at the edge.

Concrete, or inorganic material, with near zero elongation and mediocre bond strength will not perform well with feather edges or tapering. The simple lack of flexibility is a problem when impacted or if vibration occurs – coupled with pour bond strength makes the prospect of using concrete to fix concrete a bad option. However, the optimal organic elongation and strong bond strength epoxy slab-type materials, such as the 17G, bridges these concerns and provides a solution to repair concrete and tamper it out to the edges for patching areas.

The Epoxytec 17G material is formulated to tie back into itself indefinitely, never losing it’s maximum recoat window. In addition, the material can be built thin to thick (up to 12 inches).

The ability of Epoxytec 17G to have performance even at the edge gives an Owner to ability to budget for a full system rehab or sectional rehab in areas or patches.

The Epoxytec 17G is a DIY product. The material simply requires preparing utilizing uncomplicated water blasting. Once mixed, the material can be applied with minimal mobilization of human resources and equipment. In fact, the product is often installed with a simple mixing drill, trowel, forms (if vertical), and has a 2-hour pot life. With no solvents or VOCs, an application crew can apply with peace of mind.

Unlike utilizing cemetitious mortars, which typically have somewhere between 7 – 28 days to reach full compressive strength, and require extreme undercutting to repair. Epoxytec 17G reaches extreme compressive strength quickly, and requires less preparation and logistics to apply. From an operational standpoint, using this system saved the Owner from downtime which converts to cost svaings. Returning the push-wall back into service at a fraction of the speed of concrete makes the 17G an attractive candidate for uptimal operational production considerations.

Once completed, the Epoxytec 17G brought the push-wall back to service with enhanced 17,800psi compressive strength, and with sealed and protective lining capabilities. An upgraded performance system will now shield against corrosives, abrasion and high scoring impact.

Returning the push-wall back to service in rapid time (versus slow curing cementitious alternatives) translates to operational productivity. With a more durable push-wall than previous, reducing the rate of future shutdowns and repairs adds furthermore to cost reductions going forward and exponentially compounds savings indefinitely. Epoxytec’s ultimate goal is to deliver life extensions to infrastructure, and utilizing products like 17G makes these objectives realized across many industries.

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