Selecting and Sourcing Coating Systems for Water

Transcription

Selecting and Sourcing
Coating Systems for
Water Tanks
A JPCL eBook
i
Selecting and Sourcing
Coating Systems for
Water Tanks
A JPCL eBook
Copyright 2011 by
Technology Publishing Company
2100 Wharton Street, Suite 310
Pittsburgh, PA 15203
All Rights Reserved
This eBook may not be copied or redistributed
without the written permission of the publisher.
Contents
ii
Contents
Introduction
1
7
12
20
Performance or Preference: A Look at
iii
1
Selected Systems for Water Tank Interiors
by Dan Zienty, Lee Dornbusch, and Tony Ippoliti
A Comparison of Ultra-Long-Life Coating
7
Systems for Water Storage Tanks
by Michael Doolittle
Coating Systems Guide for Water Tanks
12
Coatings Company Profiles
20
Introduction
iii
Introduction
This eBook consists of two articles published in JPCL during the last
several years on the topic of selecting and specifying coatings for water
tanks, as well as JPCL Buying Guide material on coatings systems
for water works facilities in various exposure environments.
The Buying Guide is organized, ﬁrst, by exposure type, such as
“Immersion Exposure - Potable Water Approved,” then by substrate type,
ﬁrst steel, then concrete. Then, coating manufacturers are listed in alphabetical order and their preferred system is named in both proprietary and
generic terms. Finally, contact details are given for all the companies.
This collection is designed to provide general guidance on selecting
and specifying water tank coatings, and then to give sources for
acquiring the appropriate systems.
Water Tank
Interiors
By Dan Zienty and
Lee Dornbusch, Short Elliott
Hendrickson Inc., and
Tony Ippoliti, The SherwinWilliams Company
Editor’s note: This article was
published in JPCL in May 2007.
The field research project described
here received an honorable mention
award for Engineering Excellence at
the Minnesota Section of the
American Council of Engineering
Companies.
“The Anoka water
tank evaluation
revealed extensive
rust bleed and
corrosion along
the edge of the
structural support
angles, the roof
radial plate lap
joints, and similar
areas notorious for
premature coating
failures.”
1
Performance or Preference:
A Look at Selected Systems
for Water Tank Interiors
W
hile water storage tanks may vary greatly in size, style, and design,
all share a common need for maintenance or periodic reconditioning. Concrete tank exteriors, for example, are regularly protected
with acrylic or vinyl-acrylic systems in a smooth or textured finish.
And for the interiors of concrete tanks, polyurea or polyurethane
elastomers are applied to make interior concrete surfaces leak-proof.
Coating remediation in steel tanks is most common in areas of the tank that
are difficult to access for painting: interiors above the waterline, for example.
Unsealed roof lap-plate seams and intermittently welded roof support systems
represent common areas requiring coating maintenance. The evaluation and
study of the a Minnesota city’s 400,000-gallon steel water storage tank, completed
by an engineering firm in 2002, revealed a need for renovation and a unique
opportunity to conduct a test project with a new, NSF 61-approved, zinc-rich
coating.
The Proposal
Working with three partners–coatings manufacturerSherwin-Williams; the City of
Anoka, MN; and coating contractor Classic Protective Coatings–engineering firm
SEH, which had evaluated the tank, offered to conduct a side-byside test of two
interior paint systems with a single application of a moisture-cured urethane
(MCU) organic zinc-rich coating. The coating had been recently approved by NSF
International under standard ANSI/NSF 61 for use in potable water tanks. Like
traditional NSF 61-approved epoxy coatings for water tank interiors, the MCU organic zinc-rich that would be tested is approved for application without a topcoat.
The goal was to differentiate between the coating system preferences of the
owner (by applying coatings frequently used) and the coating system performance (by comparing the frequently used systems with the single application of
zinc-rich coating). According to the coating manufacturer, this test project represented the first time a zinc-rich coating on its own has been used in an actual
in-service water tower. For the purpose of this study, performance was defined as
the lack of blistering and peeling. Further, performance was to mean less than
10% corrosion—Rust Grade 4G—in accordance with SSPC-Vis 2, Standard Method
of Evaluating Degree of Rusting on Painted Steel Surfaces.
2
Completed test area: (left) epoxy/epoxy;
(upper right) zinc-rich/epoxy/epoxy;
(lower right) MCU zinc-rich
Photos courtesy of the authors
Background
Universal corrosion theory confirms that for rust to form on a
steel surface, an anode, cathode, electrolyte, and metallic pathway must be present. If any of these elements are missing, corrosion will not occur. A steel construction element—column,
girder, beam, or plate—is comprised of countless grains or
“cells” of steel. Some of the cells act as cathodes; others act as
anodes. Their proximity to one another provides the metallic
pathway needed for the transfer of electrons. Rain, snow, condensation, or potable water in a tank provides the electrolytic
component.
Corrosion is an electrochemical phenomenon. One method
to prevent corrosion is to prohibit the formation of rust by connecting a more noble or “passive” metal (steel) to a less noble
“active” metal. Less noble metals (zinc, in this example) act as
sacrificial anodic materials because providing the electrons that
protect the steel surface eventually exhausts them. The anode
provides the electrons that passivate the protected steel surfaces, making it a cathode. In the case of a water storage tank,
cathodic protection may be provided by an impressed current
system (see AWWA D104). Conceivably, lining the steel surfaces
with zinc-aluminum metalizing—a slow, very expensive, but
long-lasting alternative—could also provide passivation. One of
the authors is aware of one municipality that has experienced
very good corrosion protection using such a method.
The Anoka water tank evaluation revealed extensive rust
bleed and corrosion along the edge of the structural roof support angles; around the compression ring; between intermittent
welds, the upper shell stiffener ring, and roof; and at roof radial
plate lap joints. These locations are notorious for premature
coating failures because it is difficult to apply coating systems
in these nooks, crevices, and edges.
Condensation forms in these areas (hence, they are called “vapor areas”) and
causes premature coating failure, leading to rusting, flaking, or coating delamination. Such corrosion can lead to serious structural problems and costly repairs
if left unchecked. Depending on the design of the tank, seal welding of roof-supporting members in the vapor areas may offer a permanent yet costly solution.
However, in other tanks, seal welding cannot be done because it would prevent
the movement or expansion that has been designed into such areas.
The evaluation allowed the following question to be raised: could an organic
zinc coating alone protect the roof and roof support system from corrosion?
Would it “sacrifice itself”—act as an anode—if not over-coated, or would it have
performance similar to other barrier-type immersion-grade epoxy coating systems? Barrier coatings protect against corrosion by preventing an atmospheric
or a submerged electrolyte—in this case water—from contacting the substrate,
thereby removing one of the four components necessary for corrosion.
For decades, barrier coatings containing rust-inhibitive pigments such as lead
or zinc-chromate had been used as primers under topcoat systems on the interiors
3
Table 1: Systems Tested
of water towers to protect steel from the effects
of corrosion; however, such pigments, which
were based on heavy metals, were later deemed
detrimental to public health because of the heavy
metal content. Rust-inhibitive coatings limit corrosion by having their corrosion-preventing pigments solubilize slightly under wet conditions.
The solubilized pigments then act to passivate
the surface at the steel/coating interface. Manufacturers of coatings intended for potable water
contact have their coatings tested to determine
whether solvents or other toxins leach from the
coatings. No coatings with such leachates are approved for use in today’s drinking water tanks.
Further, coating system approval for each project in Minnesota is also required by the Minnesota Department of Health.
The engineering firm learned in 2002 that a
new MCU organic zinc-rich immersion-grade
coating received NSF approval. The manufacturer
formulated the coating so that it would receive
**Note: remaining interior areas of tank, not part of the test study region,
NSF 61-approval with or without a topcoat.
protected with this coating system.
There are practical reasons for the manufacturer’s approach to formulation. One reason is that, if the interior topcoat were
damaged in such a way to expose the NSF 61-approved zinc-rich coating, no
threat to the public would be derived from drinking water that was exposed to the
MCU zinc-rich system. In the past, during the transition to NSF 61-approved coatings, water tank interiors were occasionally Brush-Off Blast Cleaned (SSPC-SP 7)
prior to the application of “approved” coatings or coating systems. When these
coatings were damaged—or worse, if they blistered—the existing, non-NSFapproved coatings would be exposed to the stored drinking water, creating a
potential health risk.
The Case Study
Enter the Anoka water tank repair project.
The engineering firm approached the manufacturer of the MCU zinc-rich and
the City of Anoka with the idea of conducting a test project that included the application of the newly NSF-approved coating on the City’s 400,000-gallon tank.
During development, the manufacturer conducted controlled test studies on the
product, but had no “in-service” examples that would confirm its protective characteristics in water towers without a protective topcoat. To produce “in-service”
evidence of its product’s capabilities, and understanding the risks to the City of
Anoka, the manufacturer agreed to assume full responsibility for paint, contractor repairs, and inspection costs for coating failures (if any) in the test areas. The
inspection for failures would take place at the end of the two-year warranty given
to the owner. The engineering firm also received approval from the Minnesota
Department of Health for this first-of-its-kind undertaking. Given this win-win
scenario, the City approved the plan, and the engineering firm wrote the MCU or-
4
ganic zinc-rich system and the guarantee into plans and specs that were sent to
contractors.
The case study consisted of applying the three coating systems shown in Table
1 and Fig. 1 and comparing their performance. All three systems came from the
manufacturer of the singlecoat product in the test.
The City took the tank out of service in June 2003. The specifications incorporated a scope of work that included erecting a full-containment structure per
SSPC-Guide 6, Class 2A, and completely removing interior and exterior coatings.
Though the project schedule allowed seven weeks to complete the work, the contractor finished in four weeks and at $7,000 under budget, allowing the tank to
be returned to service earlier than anticipated.
Fig. 2: Condition of support angle at warranty inspection for MCU Zinc-rich
Performance Evaluation
The engineering firm conducted a followup warranty inspection in June of 2005—
two years after testing the three coating
systems—including the inspection of the
single-coat MCU zincrich. AWWA D102-03
Standard, in Section 5.2.1.General, states:
“When specified, the inside … surfaces of
the tank shall be inspected within one
year after coating work has been completed, to determine whether any repair
work is necessary,” so this two-year warranted test period provided more than
sufficient time for any problems to surface. At the engineering firm’s invitation,
representatives of the coating manufacturer participated in the inspection. The
inspection revealed no significant failures
of the single coat MCU organic zinc-rich
system when compared with the two
more traditional systems (Figs. 2 and 3).
The only notable failures occurred over a
manway cover, amounting to less than
1⁄10 of 1% of the total test area. The failure was traced to an application error, not
to the product itself (Fig. 4).
Benefits
The initial success of the MCU zinc-rich
coating, applied at 3 to 4 mils DFT, was
measured by the performance criteria established for this test project case study
(no blistering or peeling, less than 10%
corrosion per SSPC-Vis 4). This success indicated a method by which this water
community could save thousands of dol-
Fig. 3: Condition of MCU zinc-rich on roof plates at warranty inspection
5
lars on labor, material, time, and repairs needed due to corrosion of its
storage tanks. The submerged area
of the tank totaled approximately
9,000 square feet, a third of which
represented thevapor area that was
used for the case study. A manufacturer’s recommendations for conventional coatings, in vapor zones,
for example, may require a coating
thickness between 8 and 12 mils.
The recommended application
thickness for the MCU organic zincrich tested is much less, however,
and there is no visible evidence of
unsuccessful coating performance
at this thickness. At an estimated
cost average of $6.25 per square
Fig. 4: At the warranty inspection, the only notable failures were over a manway cover
foot using traditional systems,
and were traced to an application error.
recognized savings in the test area
for labor and materials were estimated at $1.75 per square foot–significant
savings, especially if the single-coat system performs as long as or longer
than conventional systems.
Since the AWWA and many water professionals recommend periodic inspection
of water tanks every three to five years, the engineering firm has another
inspection tentatively planned for 2009, at which time additional corrosion
performance results will be measured.
The performance data discovered in this two-year test project will be used to
evaluate the longevity of the MCU zinc-rich coating as an alternative to conventional multi-coat coating systems for vapor zone renovation.
Future Value
Adopting a new coating technology or employing an existing coating in a new
environment may require owners or engineers to adjust their thinking, but not
necessarily to accept greater risks. The engineering firm successfully implemented this test project case study without any risk to the client or to the safety
of their drinking water supply by providing the coating manufacturer the opportunity to assume responsibility for a product in which it had great confidence
yet limited in-service statistics.
Overcoming Client Preferences/Exceeding Owner Performance
“We had complete trust and confidence in SEH,” City of Anoka Public Works
Director Craig Gray said. “Inspectors followed the entire project, and safety tests
were conducted before the tank was put back into service to ensure public safety.
But most of all, we needed assurances that if something went wrong I did not
have to go in front of our City Council and ask for another $100,000 to redo the
job, and the agreement [the engineering firm] negotiated with the paint manufacturer to cover all labor and materials gave us the security and protection we
needed to proceed.”
6
“Really, our only concern was meeting the project timetable, as we had to have
the tank back on line by August when water demand is greatest. Though we set a
seven-week schedule, the project was done three weeks early, and the tank was
back on line the first part of July. The project just went very smoothly, and shows
the potential that exists for municipalities to substantially save on labor and materials involved in water tank painting and/or rehabilitation.”
The single-coat product SEH tested was Sherwin-Williams’ Corothane I Galvapac, B65 Series. Classic Protective Coatings applied the coatings for the testing.
Dan Zienty is a senior professional specialist for Short Elliott Hendrickson Inc. (SEH),
a multidiscipline, single-source consulting firm of engineers, architects, planners,
and scientists with offices throughout the Upper Midwest and mountain regions
(www.sehinc.com). He is based in St. Paul, MN.
Lee Dornbush is also a senior professional specialist at Short Elliot Hendrickson Inc.
He is an SSPC-certified Protective Coating Specialist.
Tony Ippoliti of The Sherwin-Williams Company, Industrial & Marine Coatings, is a
senior corrosion specification specialist based in Indianapolis, Indiana. He prepares
protective coating and lining specifications for engineering firms, steel fabricators,
electric power generators, and water/wastewater facilities in the Midwestern U.S. He
also performs corrosion surveys and assists in the evaluation of existing protective
coating and lining systems. He has worked for Sherwin-Williams since 1976. He is
active in SSPC, STI/SPFA, NACE, and AWWA.
JPCL
Specification
Development
By Michael L. Doolittle,
Tank Industry Consultants
Editor’s note: This article was published
in JPCL in May 2009.
7
A Comparison of Ultra-Long-Life
Coating Systems for Water
Storage Tanks
F
or water storage tank applications, alkyds, the much-trusted coatings of the past, were
summarily replaced by superior performing polyurethane coatings in the late 1970s and
early 1980s. Polyurethanes were then, in the early 1990s, supplanted by polyurethanes
with clear coats and polyurethanes with UV protectors—coatings that promised resistance
to fading and a twenty-year service life. These later polyurethanes are now being challenged by fluorourethane and polysiloxane coatings—coatings that, although developed in the 1980s,
are only recently being used for water storage tank applications. Fluorourethanes and polysiloxanes
are ultra-high-performance coatings that are said to have a service life of up to thirty years.
This article gives an overview of long-life coating systems for water tank exteriors and interiors,
including a relative comparison of salient application and performance properties.
Storage Tank Exteriors
Fluorourethane and siloxane coatings are rapidly gaining popularity with tank owners. The advertised thirty-year service life of these coatings is a big plus as regulations placed on coating removal
and application procedures become stricter and the costs of materials and labor rise. The product
cost, however, makes most tank owners think twice and re-evaluate the benefit of the increased service life.
Siloxane coatings, newer to the industry than fluorourethanes,
are promoted as having very good color and gloss retention, and
they are less expensive than the fluorourethane coatings. Siloxanes have a wider recommended application thickness range
and are relatively easy to apply, with pot life exceeding the fluorourethane coatings.
The fluorourethane coating system applied to these two ground storage tanks
continues to provide excellent corrosion protection after 7 and 8 years of service.
All photos courtesy of Tank Industry Consultants
Life Expectancy
What defines the end of an exterior coating’s service life? When
the first rust spot appears? When a certain percentage of primer
is showing? When a certain percentage of rust is visible? Or
when the finish coat is not aesthetically pleasing? For this article, the definition of the service life of a coating is the amount of
time before repainting becomes necessary due to coating failure
and corrosion. Future touch-up may be required on isolated
coating failures. If aesthetics are a concern, the owner may have
to topcoat the repainted tank before the end of the expected
service life. However, future topcoating would be less expensive
than complete cleaning and recoating and could postpone the
need for complete cleaning and repainting for many years.
8
Color Availability
Most exterior tank coatings are available in practically all colors. Many times, color and aesthetic concerns drive the selection of the coating.
Ease of Application
Generally, single-component materials dry on surfaces via the evaporation of the solvent, while multiple-component materials generally cure by a chemical reaction of the materials. Some coating types
are more sensitive to atmospheric conditions than others, and this should be taken into account during coating selection.
Single-component materials, such as alkyds, acrylics, moisture-cured urethanes, and silicone alkyds,
are easier to mix and apply than the two- and three-component, higher-performance coating materials.
During both application and cure, moisture-cured coatings are prone to blushing when exposed to
humidity or dew. Good painting practices must be followed for a coating to
perform as intended. For example, to perform properly, all components of a
moisture-cured urethane must be mixed using the correct component ratios
and power mixers; clean thinner in clean containers should be used as well.
In addition, most coating manufacturers recommend using shorter roller nap,
high-quality roller covers for application. The shorter roller nap is somewhat
more difficult to use—it requires the applicator to reapply the coating to the
roller more frequently because the shorter nap does not hold as much paint
as the longer nap. Care needs to be taken to apply and roll the material to
achieve the required dry film thickness.
Because of its sensitivity to coating thickness, a polyurethane clear coat
is much more difficult to apply evenly and consistently. It is critical that the
material be applied at the specified thickness—normally about 1 mil. A
polyurethane application can look great when it is completed, but once a year
or two has passed, any areas where the clear coat is too thick can yellow, and
undercoats that are too thin can begin to very noticeably fade.
Resistance to Abrasion
In reality, the sources of abrasion on a water tank surface are limited: vandals throwing rocks or shooting at tanks, or, possibly, ice and snow build-up
in cold weather. When vandals throw rocks and chip the coating, spot rusting may result. Our company’s experience shows that all of the finish coatings
are going to react similarly. If a tank has been damaged previously by vandalism, consider using a zinc prime coat in which the zinc may help reduce the
rusting caused by a breach in the finish coat. The best strategy to reduce abrasion from ice and snow is to make sure the material is applied with a smooth
finish so the ice and snow will slide off, with no lifted edges where moisture
can get in and lift the coating.
This tank in Lombard, IL, “The Lilac Village,”
is still a community landmark three years
after the tank was recoated with a
fluorourethane coating system.
Resistance to Graffiti
If the solvent in an anti-graffiti paint softens the underlying coating, graffiti will bond readily to the
underlying coating and will be difficult to remove. Ultra-high-performance coatings may reduce the
damage from graffiti because they provide a smoother finish, have lower surface energy, and are
more solvent resistant, thus giving the graffiti less “bite” into the surface. With high-performance
polyurethanes and ultra-high-performance fluorourethanes and polysiloxanes, graffiti can be removed, but it takes a lot of elbow grease using the appropriate thinner. Removing graffiti can remove part of the finish coat, and often residual graffiti is visible. The only way to “remove” graffiti
from acrylics and alkyds is to apply coating over the graffiti, but matching the color of the original
coating is often difficult.
9
Resistance to Fading (Color and Gloss Retention)
Although alkyds and acrylics can be obtained in many colors, the poor color retention and gloss retention of these coatings should limit the color selection to light blues, light greens, light tans, and
white. As these coatings fade and chalk, they will tend to look white anyway.
The higher performance polyurethanes in bright colors will begin to fade during the first three to
five years. If a tank is to be painted white, it might be adequate to use a standard polyure-thane because, while the gloss is likely to fade, the color will remain the same.
Water tank applications of solvent-borne fluorourethanes have not been in service long enough to
know how much they will fade. However, tanks that our company observed being coated with a fluorourethane three to five years ago do not appear to have faded nearly as much as we would have expected had they been painted with a standard polyurethane. Longer in-service results for water tank
applications of siloxane coatings are not yet available
A recent and common application of note is the use of fluorourethanes for bright colored logos on
lighter colored tanks because fluorourethanes hold color well.
Also of note: in our company’s experience with exterior tank coatings, acrylics seem to hold their
color significantly better than the alkyds.
Resistance to Chalking
Chalking is a white powdery substance that forms on the surface of a coating as it is degraded by UV
radiation and as the coating pigments and binders break down. Chalking is usually an aesthetic consideration, except in extreme situations in which the thickness of the coating decreases and reduces
the coating’s protective properties. Alkyds and polyurethane coatings seem to be most apt to chalk.
Ease of Topcoating
Coatings that have good resistance to graffiti (having a very hard or smooth surface) are typically not
easy to topcoat for the same reasons. Although water tank applications of fluorourethanes and siloxanes have a short history, given their short recoat windows, abrading is normally required before topcoating or touch-up; polyurethanes with clear coats also require abrading prior to topcoating or
touch-up.
Polyurethanes, acrylics, and alkyds typically have an extended recoat window. By the time they
are ready for topcoating, the surface has degraded and chalked sufficiently that a good power wash,
using a detergent and usually some scrubbing, is required to prepare the surface. By nature, chalking normally causes the surface to become abraded. To provide good adhesion for the topcoating, it
is important to remove chalk, dirt, and debris.
Dry Fallout
Coatings that dry or cure quickly and fall to the ground in a relatively dry condition have good “dry
fallout” characteristics. Because most water tank abrasive blasting projects are done inside containment due to lead paint or nuisance dust restrictions, dry fall coatings are not as critical as they once
were—the tarps or containment can easily be left in place during coating application. In addition,
more and more exterior tank painting projects are using brush and roller application instead of spray
application. Application by brush and roller will reduce the amount of overspray because the coating droplets will be larger and not travel as far.
Polyurethane, fluorourethane, and polysiloxane coatings do not have good dry fall characteristics. In addition, some of the dry fall acrylics cannot be applied by brush and roller and achieve good
results.
Corrosion Resistance
Corrosion resistance can be documented by many testing procedures that compare different coating types under similar conditions. Because lead-based primers are no longer available, many coatings, such as alkyds, silicone alkyds, and acrylics, will not have the same corrosion resistance as
previously manufactured coatings of the same generic type that contain lead or chromates.
10
Storage Tank Interiors
Two- or three-coat tank interior epoxy coating systems have been a standard in the industry for the
past 25 years. Recent additions to the coatings specifer’s arsenal are zinc-primed epoxy and
polyurethane interior coating systems. Metalized coatings, also available for 25 years or so, are also
gaining popularity for the interiors of potable water storage tanks.
Life Expectancy
Is interior coating failure defined as when the first rust spot appears or when a certain percentage of rust is visible? The service life of an interior coating is defined in this article as the typical
expected number of years before repainting becomes necessary due to excessive coating failure and
corrosion. The owner can extend the service life of the interior coating by installing and properly
maintaining and operating a cathodic protection system to help protect the interior submerged
steel surfaces that have experienced coating failure. Cathodic protection is not commonly used
with zinc/aluminum spray-applied coatings.
Epoxy or zinc-epoxy interior coatings are expected to last 15–25 years. Polyurethanes and metalized coatings have a significantly longer service life.
NSF 61 Certified Products
The National Sanitation Foundation (NSF) has established testing criteria for coatings in contact with
potable water. These criteria include protocol for bacteria growth, VOC contamination, and limits on
other impurities in the cured coating system. Most states have adopted the NSF/ANSI 61 listing procedure for tank interior coating systems; the participation status of all 50 U.S. states is provided in
the NSF report, “Survey of ASDWA Members Use of NSF Standards and ETV Reports: May 2008,”
available at http://www.nsf.org/business/water_distribution/pdf/ASDWA_Survey.pdf.
Ease of Application
Epoxy and zinc-epoxy coating systems are relatively easy to apply and have a relatively short material pot life. The higher performance interior coatings, such as polyurethanes and polyureas, are
one-application, multi-pass systems. These materials have a very short
recoat window, and, once applied and set, require significant additional
surface preparation for topcoating and touch-up. They are more difficult
than the standard epoxy systems to apply because they require special
plural-component spray guns, heaters, and other equipment, as well as a
deep anchor pattern. Specialized training and certification is also required
for the applicator, and training is recommended for the equipment operator. For the coating to perform well, the operator must make sure the
coating temperature is correct and the material is “on ratio.”
A metalized coating system is also more difficult to apply because
special contractors and equipment are needed to apply them, and a higher
degree of surface preparation is required.
One advantage to metalizing, however, is that it can be applied in the
colder winter months if proper dehumidification equipment is used. The
SSPC-CS 23.00/AWS C2.23/NACE No. 12 joint standard is an excellent
Equipment used in the application of metalized coating
guide to use for specifying and evaluating metalizing systems.
Resistance to Abrasion
Applied correctly, polyurethane coatings for tank interiors are very resistant to ice damage, which
is the only abrasion to which they are really subjected. Metalized coatings also have excellent
resistance to corrosion and abrasion.
11
Ease of Topcoating
It is not normally cost effective to topcoat standard epoxy interior tank coatings. However, when
ultra-high-performance coatings are applied correctly, they may be very difficult to remove, and topcoating may therefore be an option. With the long expected service life of ultra-high-performance
systems, the need to topcoat has not come up yet. Based on experience so far, it is expected that spot
repair will extend the life of these coatings in water tank service. However, the surface will need to
be well abraded before any spot touch-up.
Corrosion Resistance
Metalizing and a zinc primer under an epoxy or polyurethane topcoat are the only tank interior coating systems that offer corrosion resistance. Epoxy and polyurethane coatings offer a barrier, and
polyurethanes have especially good resistance to coating “undercut,” should a coating break occur.
(Undercut occurs where corrosion works its way under a coating and enables a coating failure spot
to develop.) A metalized system has excellent resistance to corrosion.
Specialized Test Equipment
High voltage holiday testing is required for polyurethane tank interior coating systems that are applied at more than 20 mils of dry film thickness. This test is more involved and more difficult to
use than the standard low-voltage test.
Cost of Materials
Metalizing is very expensive but has one of the longest life expectancies of any of the coatings discussed. A sealer or finish coat is often recommended.
Conclusion
It is important to take into consideration many criteria when designing a coating system for each
tank coating specification. Items to consider include the following.
• In what environment is the tank located?
• What are the constraints of the tank site?
• What is the design of this tank?
• What is the present condition of the coating?
• What are the types of coating failures observed on this tank, why did they occur, and what can be
done to correct them?
• Where are the existing corrosion problems on this tank?
• What time of year and for how long can the tank be taken out of service for painting?
• What are the owner’s short and long-termplans for this tank?
What is the right coating system for your water storage tank? Now, more than ever, tank owners
and operators need expert, unbiased, third-party input to make this complex decision.
Michael Doolittle has worked for Tank Industry Consultants (TIC) for 25 years. Formerly TIC’s field services
manager, he continues to be one of the primary liaisons between owners and contractors.
He conducts failure analyses, is involved in dispute resolution, attends pre-construction
meetings on behalf of tank owners and TIC, and is responsible for project administration
duties. Mr. Doolittle is a Level III NACE Certified Coating Inspector, an SSPC Protective
Coating Specialist, and an American Welding Society Welding Inspector. He has written
several articles for JPCL.
JPCL
Coating Systems
for Water Works
12
Coating System Guide
for Water Works
Listings are alphabetized by company name.
Exterior Exposure
Weathering and UV
Steel
+"1.
+1$ !01.'+% , 0"
EP521/EX-2C
Epoxy (1-2 Coats)/Urethane
,*-,/'0# #!&+,),%'#/
CarbonSeal
Epoxy/Epoxy Novolac/Epoxy Novolac
+#!,+ ,.-,. 0',+
Chemclad
Epoxy/Epoxy 100% Solids
+"1.,+ , 0'+%/ +!
Perma-Gloss
Inorganic Zinc/Epoxy/Fluorourethane
+2'.,+*#+0 ) .,0#!0'2# , 0'+%/ +!
E-4000 One Coat
Zinc-Rich, Organic
+"1/0.' )
+,0#!& +!
Nansulate PT
Thermal Spray
2')',+ +!
PPG
Epoxy/Epoxy/Siloxane
-,45 #!& +0#.+ 0',+ )
MPC Plastico
Organic Zinc/Epoxy/Urethane
+0#%1*#+0 #!&+,),%'#/ +!
FluoroGrip
Sheet Lining, Thermoplastic
)1#
0#.
.'+# +" .,0#!0'2# , 0'+%/
Marine AC70/Marine Urethane
Epoxy/Polyester/Polyester
.%,+ .*,.
Novocoat
Epoxy 100% Solids (1 or 2 Coats)
+0#.+ 0',+ ) '+0
International
,3#./ +"1/0.' )
Gulf Coast Paint
)#4!.#0# #!&+,),%'#/ 0"
Cemprotec
Epoxy (1-2 Coats)/Acrylic (1-2 Coats)
*#.'! + $#05 #!&+,),%5
AS-250
Epoxy/Epoxy/Epoxy
,4 +"1/0.'#/ +!
Fox FX-501M Elastomeric Coating
Other
,)5 -#! 101.
, 0'+%/
Futura-Thane
+"1/0.'#/
IronBond 111
Other
. ,)'+# ,*- +5
Carboxane
Organic Zinc/Siloxane
#0!,
Perlastic SG
Coal Tar/Asphalt
, 0'+%/ +!
Rustop/SP-X Silicone Poly Plus
.0 , 0'+%/ +!
HP-105
Urethane/Urethane
&#*!, +0#.+ 0',+ ) 0"
Epo-chem RL 500PF
Epoxy/Epoxy/Epoxy
!, #/0#.+
GacoFlex S20
Other
,..,/',+ ,+0.,) ,
Techni-Plus UR-5
Urethane/Urethane
,.!&#* ,.-,. 0',+
Corchem 97/260/274
(8 0 0) 7 2 2 - 6 7 2 1
.,+ .,"1!0/ +!
Mortarthane/Accelaresin
Polyurea Hybrid (1, 2, or 3 Coats)
www.3m.com/corrosion
,.,0#!& '%& #.$,.* +!# , 0'+%/
Cortech
3M Corrosion Protection Products
Organic
Zinc/Epoxy/Urethane
Scotchkote
Fusion-Bonded Epoxy (1-2 Coats)
,0#
+"1/0.'#/ +!
ABRI Industries
Durabak
18/Durabak 18 Smooth
IronBond111
Urethane/Urethane
Other
#+/, ,.0& *#.'!
Avilion
Denso Inc.
Wasser
Tape
Wraps
MCU Zinc Rich/MCU/MCU
#2,#
+0#.+ 0',+ ) '+0
Blue Water
and Protective
Devoe
High Marine
Performance
Coatings Coatings
Marine Urethane
Epoxy
(1-2
Coats)/Urethane
Epoxy/Polyester/Polyester
' Bowers
*,+" Industrial
,%#) '+0 ,*- +5
Finium
Gulf DTM-AT
Coast
Other
1.,*
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Bridgeport
HPL-1110
GA 27P
Epoxy
100%
Solids
Epoxy
100%
Solids(1(1oror2 2Coats)
Coats)
#*-#. 5/0#* *#.'!
Kemperol 2K-PUR
Urethane/Urethane
0"
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Fibre-Prime
Other
#+!# ,..,/',+ #.2'!#/
PetroGard
Tape Wraps
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Endura-Flex
Urethane Elastomeric (1 Coat)
,)' .'" , 0'+%/ +!
Polibrid 705
1)$ , /0 '+0 $% +!
GCP
,)5!, 0 .,"1!0/
Polyeuro 7502
Polyurea Pure (1, 2, or 3 Coats)
#*-#)
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17360/17630-3/5595U
,)5 -#!
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PolySpec TuffRez
#.#/'0# .,0#!0'2# , 0'+%/
CSE-6200/UC-5500
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Por-15
Urethane/Urethane
'%&) +" +0#.+ 0',+ ) +!
475R Dry-Fall/68R Dry-Fall
, 0'+%/
PPC Coatings
Other
Water Works
13
1/3&$3*5&
"1*.& /"3*.(2
Amercoat
/,5&1*.& /"3*.(2 /10/1"3*/.
LiquaTile
)*./ *.*.(2 /10/1"3*/.
SolarMax
Urethane/Urethane
/%%" "*.3 /10/1"3*/.
RoPon/Polycoat HS
/5",
/10
Roval R22 Cold Galvanizing Compound
Zinc-Rich, Organic
423 4,,&3
Rust Bullet Standard
Other
423 ,&4- /10/1"3*/.
9100/9400 System
"4&1&*2&. .$
Sauereisen
Urethane/Urethane
)&16*. *,,*"-2
Macropoxy 646/Hi-Solids Polyurethane
0&$*",38 1/%4$32 .$
Polyshield HT-100F, AMP 100, CAP 100
3*1,*.( ,/8% 1/40 ,$
Integritank
Methyl Methacrylate/Methyl Methacrylate
&1-"1423 &$)./,/(*&2
Termarust TR2000 HR CSA Series
Calcium Sulphonate
&2," "./ /"3*.(2 3%
Teslan
Zinc-Rich, Organic
3%
.&-&$ /-0".8 .$
Hydro-Zinc/UVX/HydroFlon
Organic Zinc/Urethane/Urethane
/0 &$1&3 /"3*.(2
Top Secret
Alkyd/Alkyd/Silicone Alkyd
23 &.3418 /"3*.(2 .$
FPUWC1
Inorganic Zinc/Epoxy/Fluoropolymer
/"3*.(2
EpoxyGrip/UreGrip
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FSS 50 DM
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PolyArmor, PolyPro
/,"3*,& 1&& .$
Volatile Free, Inc.
"22&1 /10/1"3*/.
Wasser
"32/. /"3*.(2 .$
Aqua-Shield
Alkyd/Acrylic/Acrylic
",*#41 /.2314$3*/. 823&-2 .$
UraLock UV
41/-"1 .$
HPL-1110
/1,%6*%&
ZRC-221 Cold Galvanizing Compound
Zinc-Rich, Organic
.%41" ".4'"$341*.( / 3%
HiBuild/EX-2C
Exterior Exposure
Weathering and UV
Concrete
.%4231*&2
Concrete Bond WR
Other
$18,* /. ,//1*.( /,43*/.2
AcryliCon - Decor
Other
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Sil-Act
Siloxane/Siloxane
.%&+ /10/1"3*/.
Polagard
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Epoxy/Epoxy/Siloxane
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Duromar
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Thermal Spray
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Thermal Spray
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Other
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Epo-chem RL 500PF
Epoxy/Epoxy/Epoxy
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Epoxy 200
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Armorgard 700UV
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Corchem 260/274
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Corotech
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Corro Aqua-Shield
Epoxy/Epoxy/Epoxy
/3&
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Urethane/Urethane
1/22'*&,% 1/%4$32 /10
Dex-O-Tex
1/6. /,8-&12
CrownPro 6 No VOC
&.2/ /13) -&1*$"
Denso
Tape Wraps
&5/&
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Devoe High Performance Coatings
.&$/. /10/1"3*/.
Chemclad
0/78 &$) .3&1."3*/.",
MPC Plastico
1(/. 1-/1
Novocoat
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Tammscoat
,&7$1&3& &$)./,/(*&2 3%
Cemprotec
Other
/7 .%4231*&2 .$
Fox FX-501 Elastomeric Coating
Other
/"3*.(2 .$
Bio-Safe Prime & Seal/MaxLife
"$/ &23&1.
GacoFlex S20
Other
"1/. 1/%4$32 .$
Moratarthane/Accelaresin
&-*3& 1/%4$32 .$
Tuff-Flex CA
Other
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Endura-Flex
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GCP
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CarbonSeal
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AC403 Elastomeric Coating
Other
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Nansulate GP
Thermal Spray
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FluoroGrip
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AS-250
Epoxy/Epoxy/Epoxy
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Futura-Thane
Water Works
14
#24 0#4+/)3 /%
HP-105
Urethane/Urethane
02203+0/ 0/420Techni-Plus UR-5
Urethane/Urethane
1'%+#-49 20&5%43 /%
Polyprime-100, Polyshield HT-100F, AMP 100
0
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Integritank
*'.%0 /4'2/#4+0/#- 4&
Epo-chem RA 500M
Epoxy Flake Filled/Epoxy Flake Filled
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CIM
'.1'2 934'. .'2+%# /%
Kemperol 2K-PUR
Urethane/Urethane
'2.#2534 '%*/0-0)+'3
Termaflex TX4000 Series
Other
'60'
/4'2/#4+0/#- #+/4
Epoxy/Epoxy/Epoxy
'9 '3+/ 0.1#/9
Plasti-Chemie
/'.'% 0.1#/9 /%
EpoxoBloc WB/Enviro-Crete
520.#2 /%
HPL-1110 PW
2940/ /4'2/#4+0/#- /%
Krystol T1, Krystol T2
Other
01 '%2'4 0#4+/)3
Top Secret
Alkyd/Alkyd/Silicone Alkyd
/'%0/ 02102#4+0/
Chemclad
/%
Marseal 4000
024*'2/ /&5342+'3 /%
Hydro-Seal 75
Epoxy Novolac (1 or 2 Coats)
34 '/4529 0#4+/)3 /%
FPUWC1
Epoxy (1-2 Coats)/Fluoropolymer
/6+20-+/' /4'2/#4+0/#- #+/4
Enviroline
0#4+/)3
EpoxyGrip/UreGrip
1089 '%* /4'2/#4+0/#Uroflex 61
08 2'4' 20&5%43 2051
Nox-Carb Stain & Sealer
Siloxane/Siloxane
'23# -'8 /%02102#4'&
FSS 45 DC
2)0/ 2.02
ErgonArmor
Coal Tar/Asphalt
#%+(+% 0-9.'23
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Elasto-Deck 6500
'8%0/ *'.+%#-3
Powercoat
-'8%2'4' '%*/0-0)+'3 4&
Cemprotec
Other
0-+$2+& 0#4+/)3 /%
Polibrid 705
+3520/ '%*/0-0)+'3 /%
PolyArmor, PolyPro
#%0 !'34'2/
GacoFlex LM 60
0-9%0#4 20&5%43
Polyeuro 7502
0-#4+-' 2'' /%
Volatile Free, Inc.
-0$#- %0 '%*/0-0)+'3
Endura-Flex
0-9 1'%
*+0,0PolySpec TuffRez
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MCU/MCU/MCU
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Urethane/Urethane
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Aqua-Shield
'2'3+4' 204'%4+6' 0#4+/)3
Heresite CSE-6000
Epoxy/Epoxy/Epoxy
0.103+4' '%*/0-0)+'3
CarbonSeal
0#4+/)3
PPC Coatings
Other
!0-6'2+/' 0#4+/)3 02102#4+0/
LiquaTile
/&520/ 0#4+/)3 /%
Perma-Clean 100 Ceramic Epoxy
204'%4+6'
#2+/' 0#4+/)3
Amercoat
"
/&5342+#- 0#4+/)3 0( 0-02#&0
Multiple brands
20('33+0/#- 20&5%43 0( #/3#3 /%
Professional Water Sealant PWS-5 Regular
Other
2030%0 /%
Weather Seal
Siloxane/Siloxane
#+/)5#2&
Clear Seal
Urethane/Urethane
*+/0 +/+/)3 02102#4+0/
SolarMax
Urethane/Urethane
0&&# #+/4 02102#4+0/
RoPon HS/Polycoat HS
534 -'5. 02102#4+0/
9100/9800 System
#5'2'+3'/ /%
Sauereisen
Urethane/Urethane
*'27+/ !+--+#.3
Macropoxy 646/Hi-Solids Polyurethane
#-+$52 0/3425%4+0/ 934'.3 /%
AntiCarb S
Other
Immersion Exposure
Potable Water Approved
Steel
! *'34'240/ 0
0.103+4'3
ARC PW
/&5342+'3
Abri Universal Sealer - Marine
Other
6+-+0/ /%
PPG
07'23 /&5342+#Duromar
#2$0-+/' 0.1#/9
Carboguard
Epoxy/Epoxy/Epoxy
0/ '%* 0( #-+(02/+# /%
Hydro-Pox
/4')5.'/4 '%*/0-0)+'3 /%
FluoroGrip
/4'2/#4+0/#- #+/4
Enviroline
! '6%0/
Brushable Ceramic
Epoxy/Epoxy/Epoxy
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Protec II
#4+0/#- #+/4'/#/%' 20&5%43 49
Jaxxon
4&
1'%+#-49 20&5%43
NSP-120 High Performance Epoxy Coating
0-+$2+& 0#4+/)3 /%
Polibrid 705
0-9%0#4 20&5%43
Polyeuro 5502 NSF
Water Works
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Raven Lining Systems
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Sauereisen
Urethane/Urethane
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Copoxy Primer/Mac 646 PW
Epoxy/Epoxy/Epoxy
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Watersafe Primer, Watersafe 100-NSF Polyurea
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SpectraGarde
Urethane/Urethane
Water Works
15
Immersion Exposure
Potable Water Approved
Concrete
'$01$/1,+ ,
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ARC PW
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Abri Universal Sealer - Marine
Other
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Sil-Act
Siloxane/Siloxane
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PPG
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Duromar
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Reactamine
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Epo-chem RA 500M
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Epoxytec CPP
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Coal Tar/Asphalt
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Other
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Cemprotec
Other
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Spraywall/Sprayshield
Urethane/Urethane
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Other
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Thermal Spray
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Organic Zinc/Epoxy/Epoxy
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AquaVers 405
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EpoxySeal PW
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(02/,+ $"'+,),&($0 +"
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Water Works
16
8,.,10 0&
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Cem-Flex ST
Other
14214$6,10
Elastocoat
Urethane/Urethane
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Endura-Flex
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SpectraGarde
Urethane/Urethane
0'7564,$. 1$6,0*5 1) 1.14$'1
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Powercoat
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Duromar
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Carboguard
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Ceilcote
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Coal Tar/Asphalt
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Epo-chem RA 500M
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CIM
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Corchem 247
Epoxy Coal Tar High Build (1 or 2 Coats)
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Corotech
Epoxy/Epoxy/Epoxy
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Uroflex
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Novocoat
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CarbonSeal
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Sheet Lining, Rubber
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Other
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Epoxy Phenolic (3 Coats)
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Water Works
18
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LiquaTile
645 6--&5
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Other
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9100 System
Epoxy/Epoxy/Epoxy
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Selecting and Sourcing Coating Systems for Water

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