Specs_Eastside WWTP Sludge Tanks Lining.pdf

USDA

Agricultural Research Services (ARS)

Beltsville Agricultural Research Center (BARC) Utilities Management Unit (UMU)

TANKS LINING SYSTEM SPECIFICATIONS

1.0 GENERAL

1.1 Work Included

A. The contractor shall furnish and install/apply a Tank Lining System complete and operational for both tanks per the provided specifications.

B. Work shall include all labor, materials, equipment, and incidentals necessary and required for the lining system to be complete and operational as specified.

1.2 Performance Requirements

A. The main goal for the use of this lining system on the tanks is to protect the tank steel structure from further corrosion caused by the corrosive nature of the liquid it holds (wastewater sludge). To fully protect the tank steel structure, the liner system shall be completely free of any defects, holes or imperfections that could lead to the sludge reaching the steel of the tanks behind the liner system.

1.3 Warranty

A. The liner system materials and installation shall be guaranteed free of defects by the manufacturer and installer for a period no less10 years from the installation date.

1.4 Unit Responsibility

A. Furnishing and applying the liner system shall be the sole responsibility of the Contractor.

1.5 Qualifications and Quality Assurance

A. The Contractor or Subcontractor responsible for the installation of the tanks lining system shall be certified by the lining system materials manufacturer

1. Provide Manufacturer Certification of application company training and approval of application equipment.

2. Provide Manufacturer Certification of individual applicators certifying that the applicator received the required manufacturer's training and is certified by the manufacturer to apply their product.

Beltsville Agricultural Research Center (BARC)

B. Submit to the Engineer certified test data and a letter of certification from the manufacturer that states the liner system material conforms to the specification requirements.

C. Materials shall conform to the Lining System Manufacturer’s most recent product Technical Data Sheet information.

1.6 Performance Testing

A. The aerator shall be factory tested for sound component and optimum operation parameters including temperature, proper assembly, non-clog impeller and performance under operating conditions. The manufacturer shall provide factory testing results to the owner for verification. Performance testing shall also be administered onsite after installation, the manufacturer representative shall be available onsite for such testing with the appropriate equipment to measure oxygen transfer rate and mixing capabilities.

1.7 Submittals

A. General:

1. Schedule submittals well in advance of the need for the material or equipment for construction. Allow time to make delivery of material or equipment after submittal is approved

2. Develop a submittal schedule that allows sufficient time for initial review, correction, resubmission and final review of all submittals. The OWNER will review and return submittals to the CONTRACTOR as expeditiously as possible and within a maximum period of two weeks.

3. Within one week of contract award and notice to proceed (NTP), the contractor shall submit all administrative submittals. Administrative submittals shall include but are not limited:

i. Project schedule

ii. Schedule of values

iii. Submittals schedule

iv. List of subcontractors (if any)

4. Submit Shop Drawings in accordance with the requirements of this specifications for the liner system.

5. The OWNER’S review of submittals covers only general conformity to the contract documents. The CONTRACTOR is responsible for any errors, omissions, or deviations from the Contract requirements. Review of

Beltsville Agricultural Research Center (BARC) submittals in no way relieves the CONTRACTOR from his obligation to furnish required items according to the contract documents.

6. Submit five (5) copies of documents unless otherwise specified in the contract documents. In addition, one electronic copy of each submittal shall be furnished to the OWNER.

7. Action Submittal Dispositions: OWNER will review, mark, as appropriate, and distribute marked-up copies as noted:

APPROVED: CONTRACTOR may incorporate product(s) or implement Work covered by submittal.

APPROVED AS NOTED: CONTRACTOR may incorporate product(s) or implement Work covered by submittal, in accordance with ENGINEER’s notations.

PARTIAL APPROVAL, RESUBMIT AS NOTED: Make corrections or obtain missing portions, and resubmit. Except for portions indicated, CONTRACTOR may begin to incorporate product(s) or implement Work covered by submittal, in accordance with OWNER’s notations.

REVISE AND RESUBMIT: CONTRACTOR may not incorporate product(s) or implement Work covered by submittal.

8. Distribution of all submittals will be made as follows: Four copies of the furnished submittal will be retained in OWNER’s file. Remaining copy returned to CONTRACTOR appropriately annotated.

9. Apply CONTRACTOR'S stamp, certifying that the items have been reviewed in detail and are correct and in accordance with Contract Documents, except as noted by any requested and approved variance. As a minimum, Contractor's Stamp shall include:

i. CONTRACTOR'S name.

ii. Certification statement that the CONTRACTOR has reviewed the submittal and it is in compliance with the Contract Documents.

iii. Signature line for CONTRACTOR.

10. Provide Quality Control Submittals as follows:

i. Operations and Maintenance Data and manuals.

ii. Manufacturer’s Certification of Compliance that the supplied liner system is identical to the requirements of these specifications.

Beltsville Agricultural Research Center (BARC)

iii. Manufacturer’s Certificate of Proper Installation.

iv. Manufacturer’s certification of proper installation as specified.

v. Manufacturer field inspection, installation verification and testing Report.

B. Shop Drawings as a minimum shall include:

1. Liner materials type, and details including all material properties.

2. Complete catalog information, descriptive literature, application thicknesses dimensions and drawings, cut sheets, Specifications, identification of materials of construction.

3. Performance data and liner materials testing reports.

4. Product technical data sheets.

5. Materials safety data sheets

6. Certification of conformance to these specifications.

7. Shipping and storage instructions.

8. Trained, approved and manufacturer certified applicators certificates.

9. Installation plan and details, the plan shall include the following as a minimum:

a. Methods and details of initial tanks cleaning

b. Methods and details of surface preparation

c. Disposal of debris created from surface preparation

d. Lining system installation/application process, thicknesses, application methods, recommended application equipment, recommended weather conditions and temperature during the application process, C. Provide Quality Control Submittals as follows:

1. Operations and Maintenance Data and manuals.

2. Manufacturer’s Certification of Compliance that the factory finish system is identical to the requirements of these specifications.

3. Manufacturer’s Certificate of Proper Installation.

4. Manufacturer’s Training Program.

5. Equipment Testing and Field Startup Report.

Beltsville Agricultural Research Center (BARC)

2.0 PRODUCTS

2.1 Manufacturers

A. Subject to compliance with requirements, manufacturers that may be used include:

1. OBIC, LLC.

2. Approved equal.

2.2 Lining System Materials

A. All liner materials shall be manufactured at an ISO 9001 facility.

B. Primer Layer:

1. Primer layer shall be a fast-curing modified polymer primer and shall be formulated for steel surfaces as well as glass lining surfaces. Primer shall achieve an adhesion to the existing steel or glass lining surface greater than 400 psi. Primer shall be OBIC Prime 1500 or an approved equal.

C. Adhesion Layer:

1. Adhesion layer shall be100% solids, no volatile organic compound (VOC), moisture tolerant, elastomeric polyurea to provide corrosion protection and stop infiltration. Adhesion layer shall be OBIC Armor 1000 or an approved equal.

2. Adhesion layer material shall be capable of curing properly given the project site conditions and temperatures, and shall conform to the following minimum physical requirements:

PROPERTY VALUE

Hardness, ASTM D2240 D 52

Tensile strength, ASTM D412 4,000 psi

100% Modulus, ASTM D412 1,460 psi

200% Modulus, ASTM D412 1,960 psi

300% Modulus, ASTM D412 2,650 psi

Tear resistance/DIE-C, ASTM D624 445 psi

Ultimate elongation, ASTM D412 425 %

Taber Abrasion, CS17 Calibrase 23 mg loss

Flexibility, ⅛” Mandrel Pass

Beltsville Agricultural Research Center (BARC)

SWAT, ASTM G210 Pass

D. Surface Layer:

1. Surface layer shall be a two-component seamless rigid polyurethane backing material with high closed cell content. Surface layer shall be OBIC Armor 1306, or approved equal.

2. Surface layer material shall be capable of curing properly given the project site conditions and temperatures, and shall conform to the following minimum physical requirements:

PROPERTY VALUE

Density, ASTM D1622 6-8 pcf

Compressive Strength, ASTM D1621 130-180 psi

Closed Cell Content > 94%

Water Absorption < 0.03 lbs/sf

Maximum Service Temp 180 deg F

Viscosity (A side) @ 72 deg F 675 cps

Viscosity (B side) @ 72 deg F 2 00 cps

SWAT, ASTM G210 Pass

E. Armor Layer:

1. The Armor layer shall meet the same requirements as the adhesion layer specified above.

2.3 Repair Materials

A. Subject to compliance with the lining system Manufacturer’s requirements, the following products shall be acceptable as compatible repair base coat material:

1. 100% solids, solvent-free epoxy grout specifically compatible with the lining system.

2. Factory blended, rapid setting, high early strength, fiber reinforced, non-shrink repair mortar that can be applied by trowel or pneumatically spray applied, if specifically formulated to be suitable with the lining system.

3. A hydraulic cement and/or plug shall be used to stop active infiltration.

The hydraulic cement and plug shall be suitable for the lining system, and shall be approved by the lining system manufacturer.

Beltsville Agricultural Research Center (BARC)

3.0 EXECUTION

3.1 General

A. Contractor and Applicator shall take appropriate actions to comply with federal, state and local regulatory and other applicable agencies with regard to environment, health and safety.

B. All liner system installation operations including surface preparation shall ONLY be conducted by properly trained and manufacturer-certified personnel.

C. Installation of the lining system shall not commence until the tank surfaces are adequately prepared in accordance with this specification and the lining system manufacturer recommendations.

3.2 Surface Preparation

A. Conduct surface preparation program to include monitoring of atmosphere for hydrogen sulfide, methane, low oxygen or other gases, approved flow control equipment, and surface preparation equipment.

B. Initially, the Contractor shall remove all debris and obstructions from the tank.

Heavy debris on tank walls may require pressure washing or hydro-blasting to remove.

C. After the defects in the structure are identified, the Contractor shall repair all steel holes, cracks and punctures with a method that will accept the surface preparation and/or the specified liner system.

D. After removal of any heavy debris, abrasive blasting will be used to produce a clean and profiled surface. A minimum of an SSPC-SP 6 Commercial Blast and a 3 mils profile shall be achieved for the surfaces to receive the high performance the specified lining system.

E. Surface preparation methods may include high pressure water cleaning, hydro blasting, abrasive blasting, grinding, detergent water cleaning or a combination of these methods. The surface preparation shall be suited to provide a surface compatible for installation of the liner system. Applicator shall maintain strict adherence to applicable NACE and SSPC recommendations with regard to proper surface preparation.

1. For the glass lined steel tanks, surface preparation to receive the primer layer shall be accomplished through abrasive blasting for a minimum surface profile of 3 mils and no more than 6 mils.

Beltsville Agricultural Research Center (BARC)

2. It is up to the contractor to select the surface preparation method (in this case abrasive blasting) that will attain the required surface profile.

3. It is up to the Contractor and the Lining System Manufacturer to decide the method for measuring the surface profile. Digital gauge depth micrometers are acceptable as well as replica tape.

F. After surface preparation is completed spent abrasive blasting material shall be removed from the tank and properly disposed of.

G. Tank walls, floors, or other surfaces to be coated will be cleaned using compressed air and/or vacuuming to remove dust.

H. Install masking or containment as necessary to protect internal components from overspray.

I. Surface preparation method shall produce a cleaned, abraded, and sound surface with no evidence of contaminants or debris and shall display a surface profile suitable for application of liner system. Existing coatings which may affect the performance and adhesion of the lining system shall completely be removed.

J. After cleaning and before beginning the lining process, inspect the tank to ensure surfaces are properly prepared and there are no obstructions that would hinder the lining process. The lining system manufacture representative shall inspect, accept and certify the surface preparation application and provide a certificate with such acceptance that shall be submitted to the owner.

3.3 Repair Materials

A. Repair materials shall be used to fill voids, structurally reinforce and/or rebuild surfaces. Repair materials shall be compatible with the lining system and shall be applied in accordance with the manufacturer’s recommendations.

B. Subject to compliance with the lining system Manufacturer’s requirements, the following products shall be acceptable as compatible repair base coat materials for lining system:

1. Metal works repairs methods including metal holes plugging, bolted repair methods, welding, steel patches, … etc.

2. Hydrophobic and/or Hydrophilic polyurethane chemical grouts used to stop active infiltration. The chemical grouts shall be suitable for the polyurea top coating and shall be approved by the lining system Manufacturer.

3.4 Liner System Material Installation

Beltsville Agricultural Research Center (BARC)

A. Control the temperature and humidity in the tank according to the lining system manufacturer’s recommendation. Measure and record the temperature and humidity.

B. Application procedures shall conform to recommendations of the lining system manufacturer, including safety, materials handling, mixing, environmental controls during application, and spray equipment.

C. Spray equipment shall be specifically designed to accurately ratio and apply the liner system.

D. The installation begins with the application of Steel Primer Layer. Following the manufacturer’s recommended installation instructions apply the primer at a thickness of 5 to 10 mils.

E. Adhering to the manufacturer’s recommended recoat window for the primer, begin the application of the lining system Adhesion. This application thickness should be between 40 and 50 mils.

F. Apply the Surface Layer of the lining system, the Polyurethane Closed Cell Foam Surfaced at an average thickness of 400 to 450 mils.

G. Finally apply the final layer of the lining system at an application thickness of 50-60 mils.

H. Application of multi-layer/component liner system as noted above shall be in strict accordance with the lining system Manufacturer’s recommendation.

Final installation shall be a minimum of ½-inch DFT (500 mils).

I. Application of Polyurea and Polyurethane components must be completed using heated, high pressure, dual proportioning equipment approved by the manufacturer.

3.5 Field Quality Control

A. The manufacturer representative shall be available to inspect and certify the acceptance of surface preparation as well as the application of each layer of the liner system including the primer layer. Certificates of inspection and soundness of the installation shall be submitted to the owner.

B. The Contractor, the Applicator and manufacturer representative shall Complete a visual inspection to detect any defects.

C. Structures shall be tested using a high voltage holiday detection system to determine if any holidays (voids) exist in the lining. The sensitivity control of the holiday tester shall be set to accommodate the thickness of the applied lining, 100-125 volts for each 1 mil thickness. Follow the guidelines of the

Beltsville Agricultural Research Center (BARC) holiday detection system manufacturer for correct control settings. All detected holidays shall be marked and repaired in accordance with the liner manufacturer’s recommendations and at no cost to the owner.