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northeastern municipality constructed a new water treatment facility that incorporated four filter
bed tanks, whose walls were constructed of concrete. The walls of the tanks were coated with a two
coat polyamide epoxy coating system, suitable for contact with potable water. The recommended
dry film thickness for each coat was 4 to 6 mils. The concrete walls were originally coated in May,
1992; additional coating was applied during July, 1993, to repair failing areas on the concrete walls.
The initial method of surface preparation involved acid etching the concrete wall surfaces. Several
months after the acid etching was performed, the concrete walls were power washed to remove
dust and debris that accumulated during the construction of the facility.
Two months after the water treatment plant had been in service, it was reported that the coating
system was covered with liquid filled blisters. The presence of the liquid Mod blisters produced the
need for extensive repairs to the concrete walls of the filter bed tanks. Repair procedures included
water blasting the entire surface to remove all contaminants, as well as hand tool cleaning the
surfaces in accordance with. SSPC-SP 2, to remove all the blisters and feather the edges of the
remaining intact coating. As a result, large areas of previously applied, intact coating remaining on
the concrete substrate. The identical coating system was then applied to the walls.
Several days after the coating system was applied and aproximately two days before the tanks
were filled with water, a representative from the paint manufacturer visited the jobsite and noted a
strong solvent odor in the building. The epoxy coating system was rubbed with Q-tips soaked with
methyl ethyl ketone (MEK) and a significant color transfer was noted after only two double rubs.
Mobile heating equipment was then moved into the building and the coating system was forced
cured for the next forty-eight (48) hours. The paint manufacturer's representative found the coating
system to remain moderately solvent sensitive, even after forced curing.
Approximately one month after the tanks were refilled with water, the coating system was beginning
to peel from the filter bed tank walls. After two unsuccessful attempts to apply the coating system to
the concrete walls, KTA-Tator, Inc. was contracted to determine the cause of the coating failure and
to recommend appropriate repair procedures.
Field Investigation
The field investigation involved examining the filter bed mks that had blistered and been repaired as
previously described. Filter bed tank "A" had areas of peeling paint that measured several square
feet in size. The coating system was only peeling on the walls facing south and east. The walls
facing west and north did not exhibit any signs of failure. The largest areas of spontaneous peeling
were below the water-line. The peeling paint appeared to be only the repair coat. The originally
applied coat which exhibited areas of previous blistering, was exposed after the repair coating
peeled.
Filter bed "B" had not been repaired. An extensive number of blisters were observed. The blisters
measured approximately 1/4" in diameter. Approximately 25 to 30% of the total surface area below
the water-line was covered with blisters. Blisters were liquid filled, and samples of blister liquid were
removed with a hypodermic needle. Portions of the walls above the water-line had not blistered and
appeared to be unaffected. In areas where the coating had not blistered or areas immediately
adjacent to blisters, the coating system was intact and tightly adherent to the concrete walls.
Samples of failing and non-failing materials were removed from both Tank "A" and Tank "B" and
returned to the KTA laboratory for analysis.
Laboratory Investigation
Infrared analysis of the soft, peeled coating removed from filter bed tank "A" revealed amide without
the characteristic bands of an epoxy. Apparently, the peeled paint was the polyamide component of
the coating system without the addition of the epoxy component.
The blister liquid that was removed from the blisters in Tank "B" were analyzed using gas
chromatography and ion chromatography. The analysis performed using gas chromatography
revealed that organic solvents were not present; the blister contained only water.
An analysis of the blister liquid using ion chromatography revealed the presence of water soluble
salts. The ions detected and corresponding concentrations are presented in the chart below.
Ions
PPM
Chlorides
370
Bromides
850
Nitrates
300
Sulfates
1800
Nitrites
Phosphates
Nitrites and phosphates were not detected. Analysis of concrete removed from a wall in filter bed
Tank "B", revealed the following concentrations of soluble salts also listed in parts per million:
Ions
PPM
Chlorides
600
Nitrates
540
Nitrites
150
Sulfates
1550
Bromides
280
Phosphates
570
A second sample of concrete was also analyzed, yielding the following results:
Ions
PPM
Chlorides
390
Nitrates
235
Nitrites
230
Sulfates
1700
Bromides
90
Phosphates