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Project: |
Containment Pond Repair
Silicon Manufacturing Facility
Tecumseh, Michigan
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| Problem: |
Severe water loss in primary and secondary containment ponds due to aged and failing hypalon membrane liner. Repair of the exiting liner preferred for cost reasons. The liner failure was a major ongoing problem, but replacing the liner was not economically feasible. |
| Solution: |
Mike Francis, president of Protective Coating Technologies LLC offered a unique solution. He proposed to install ElastoGard ARC-HP, a pure polyurea spray coating manufactured by Elastomer Specialties Inc, directly over a geotextile fabric. The manufacturer decided to contract with PCT for this high-pressure spray application solution. |
| Materials: |
ElastoGard ARC-HP, a 100% solids pure polyurea coating developed for application on concrete, steel, geotextile fabric, wood and other substrates.
Geotextile Fabric: a 4 oz. Non-woven geotextile fabric was specified for Phase I; a 12 oz. Non-woven geotextile fabric was specified for Phase II.
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| Installation: |
Thorough cleaning of existing hypalon membrane liner and removal of existing water from containment area. Once hypalon was cleaned, the Phase I geotextile fabric was installed directly over, overlapping seams 6-8 inches and sprayed with ElastoGard ARC to form bonded seam. Phase I took a seven-man crew 2 weeks to complete, Phase II required only 5 days with the same crew. Vertical support pipes were also coated during Phase II completing a watertight system. Owner was able to return containment areas back into operation the same day.Minimum of 80 mils of ElastoGard ARC-HP was specified as the final film thickness. Overall size of contract: 40,000 square feet (both ponds). Protective Coating Technologies LLC operated two mobile spray rigs: GlasCraft MH with a Fusion gun and a GlasCraft MX with Probler PT gun. A minimum of 300 feet of hose was attached to each spray unit. |
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