PROCESS SEWER SYSTEMMANHOLE AND SUMP REPAIR

PROJECT 2777002

Introduction

After a review of the process sewer system integrity during the week of June 28,1992,CIBA-GEIGY management at Newport decided that the major manholes, sumps and liftstation would be repaired prior to the start-up of the plant. This decision was made on thebasis of the review of the data which was collected by Groundwater Technology during theplant shutdown. This repair work included the sumps in the Crude Production, Milling Areaand Tank Farms, manholes along the main process sewer line down River Street, the LiftStation prior to Waste Neutralization, and the three Waste Neutralization Tanks. A list of theitems repaired as well as plant map indicating locations is provided with this report.

Action Plan

In order to accomplish this task without delaying the start-up of plant operations onJuly 7, 1992, a team of specialty contractors and plant personnel was quickly organized for around-the-clock operation tocompletethisproject. Thecontractorsincludedaconcrete/gunitecompany, an environmental remediation company, and the consulting firm which performedthe initial investigation. Work was initiated on Friday, July 3,1992 and completed by SundayJuly 5, 1992.

The application of the various liners was based on the existing materials of constructionand integrity of the various sumps and manholes. The various liners consisted of gunite, foaminjection, Thoroseal, a furan mortar,and an Epoxy . Literature on the sealing materialscharacteristics and applications techniques has been provided in the appendix of this report.Prior to the new application, each unit was water blasted, vacuum-dried, and sandblasted toensure proper adhesion of the lining.

Prior practice in the production area involved installation of deep sumps to allow fordecantation of immiscible fluids and solids settling. This practice is no longer applicable to theproduction area. As part of this project, three sumps, A-27, A-32, and A-35, had their levelselevated to reduce accumulation in these areas. Polyurethane foam injection was injected toseal cracks or degradations where warranted.

AR3I7796PROJECT 2777002 (rev. 0) 1

Relined Areas

AREA REPAIR TECHNIQUE NOTES

Lift Station Foam Injection/Furan Mortar# 11 Manhole Foam Injection/Furan Mortar# S10 Manhole Foam Injection/Furan Mortar# 9A Manhole Foam Injection/Furan Mortar# 8 Manhole Foam Injection/Furan Morter# 8A Manhole Foam Injection/Furan MortarA-120 Sump Furan Mortar/Gunite Flapper placed on

trench inlet* A-27 Sump Furan Mortar/Gunite Sump level raised

A-32 Sump ! Gunite/Thoroseal Lower sump level raisedA-35 Sump Gunite/Thoroseal Sump level raised62 Reactor Sump Furan Mortar/ThorosealA-28 Sump(RR Track) Furan Mortar/ThorosealSitol Sump Furan Mortar/ThorosealA-54 Tank Farm (3) Foam Injection/Furan Mortar Interconnectingunderground

Gunite line in dike sealedA-100 North Sump Gunite/Thoroseal

* Cooling Tower CB Gunite/Thoroseal Plugged line clearedWaste Neutralization Epoxy ResinTanks (3)

* not included as part of GTI Report, C-G decision to additionally seal

AR3I7797,PROJECT 2777002 (rev. 0) 2

Project Costs

The following costs are associated with the completion of this project:

1. Sewer Integrity Testing $ 80,1002. Sump and Manhole Cleaning $ 16,7003. Sump and Manhole Relining $ 43,7004. Waste Neutralization $ 7,5005. Engineering $ 4,500

TOTAL $152,500

PROJECT 2777002 (rev. 0) A R 3 I 7 7 R

f-TFURAN RESI

Dairy floor with 8" x 4" x i - 3/16" pavers bonded with Sauereisen Setting Bed No. 26and No. 21C vertical joints.

PHYSICAL PROPERTIESAbsorption (ASTM C-413) ____________________<0.05%Bond strength (ASTM C-321) i >170 psi (11.9 kg/cm2)Color__________________________________BlackCompressive strength (ASTM C-579)_________13,300 psi (931 kg/cm2)Density (ASTM C-905) D Meets U.S.D.A. standard,Mortar j 98 pcf (1.571 gm/cm3)Gf0ut_____________._____________96 pcf (1.538 gm/cm3)Maximum service temperature____ _______ 350°F(176°C)Mix ratio (Power to liquid, by weight)Mortar ; 2 to 1

1.5to1

Sauereisen Furan Resin No. 21C is acomponent, 100% carbon-filled bon _mortar/grout for chemical-resistant ma-sonry units and quarry tile. No. 21C andchemical-resistant masonry units used witha suitable membrane form a completesystem to protect concrete or steel sub-strates from attack by corrosive chemi-cals.No. 21C is used in the construction offloors, sumps, trenches and tanks inchemical processing, water treatment,pharmaceutical, power, food and bever-age plants; pulp and paper, textile, andsteel mills; dairies; laboratories; and metalfinishing operations.No. 21C exhibits resistance to a widerange of acids (including hydrofluoric), al-kalies and most solvents up to a continu-ous operating temperature of 350°F.No. 21C is not recommended for exposureto hyppchlorites or oxidizing agents suchas nitric acid, chromic acid or greater than50% sulfuric acid. Refer to Sauereisen'sChemical Resistance Chart for suitabilityin specific chemical service.No. 21C complies with ASTM C-395,"Standard Specification for Chemical-Resistant Resin Mortars," andASTM C-658, "Standard Specification forChemical-Resistant Resin Grouts." Itbe used in accordance with ASTM C"Standard Practice for Use of ChemlResistant Resin Mortars," and ANSI/ASC-723, "Standard Practice for Chemical-Resistant Resin Tile or Brick Grouts."No. 21C meets the requirements of theMeat and Poultry Inspection Program ofthe U.S. Department of Agriculture for usein federally inspected meat and poultryplants.

CHARACTERISTICSG Resists wide range of acids, alkalies

and most solvents.

ntor

VSTM

3 100% carbon-filled.D Withstands temperatures to 350°F

(176°C).

___________________________________Shrinkage (ASTM C-531)____ ________ 0.35%Tensile strength (ASTM C-307)____________2600 psi (182 kg/cm2)Physical properties wtr* determined on specimens and yield different resirtts; therefore, dati ere subjectprepared under laboratory conditions using applicable 'o reasonable deviation. Data should net be used forASTM procedures. Actuil field conditions may vary specification purposes.

...since 7899

AREA PREPARATION Installation accomplished by cnipping orBricklayers 'procedure. Apply the mor- sandblasting.

Temperature of working area tarby buttering the clean, dry masonryOpt.mum temperature for handling un|ts w,,h g Jmj trowe| SQ[ ,h£ SHELF LIFE

55°«i S nfKSS betoZ 650F ^^ ^S in P'aCe 3nd P°Slti°n by No- 21 Ll^ld Resin and Powder havenandlina DraoSIs are aSSSd and tapping t0 f°rm an average Vs" Wlde a shelf life of one (1) year when stored•Iria become Sff and dfffiSft joint' Strike extruded m0rtar off face of i" unopened, tightly sealed containers

No 2f c an L aLl?ed to su the mas°nry umt with a trawel-"For in adry location at 7X)»F. If there is doubttte^DilturesaflotLsooF- fl°0rs where aPPearance * a factor, as toytne quality of the materials,

-oweve curnafs regarded S waxed face units are recommended. consu|t a Sauereisen Cements.owever, curing is retarded. At See estimating table for coverage. reoresentativetemperatures above 80°F, the working s s representative.time decreases. It is recommended that Tilesetters' procedure. The masonry ~Airrir%lutrie resin be cooled by placing the pail units or quarrY tile must have waxed CAU I IONn a large container filled with water and fat_?s- Place a quantity of grout onto the Uqujd Resin No 2i js combustible. The•ce. or storing in a cool area when surface of the previously set masonry resin contajns furfuryl alcohol, whichtemperatures exceed 80°F. units or quarry tile. Using an American can cause headaches, nausea, andSurface orenaration Olean K&R or Groutmaster Epoxy Floor s{ jn the skjn Tne vapor is harmfu, andSurface preparation Trowel, spread and work the grout ran ra..ep irritation to skin eves andAll surfaces in contact with No. 21 must across the surface of the masonry units COuS memb anes Use with ade-be clean, dry and free of contam nants, Or auarrv tile at a 45" anale to fill the mucous mempwries. u=>« w u, «uo-...rh _. d L riirt nrpfl<sp nr nil ?/ »• • V A! /N- .u ° - ? .?. quate vent Nation during mixing andsucn as oust, ain, grease or on. i/4» joints. After filling the joints in this aoolicationA em i^A-rir\M manner, remove the excess from the _MKV *,'„... u ,,.,_» i.- v.APPLICATION surface of the masonry units or quarry Powder No- 21IS a harmful dust, whichMixing tile using the trowel as a squeegee. See contames amme. The dust can causeFor bricklayers' buttering procedure, estimating table for coverage fVe- f j" fnd mucous membrane imta-use 2.5 parts Powder to 1 part Liquid Remove wax after three days at 73°F. SsLa Wash Sfbr? eSrResin, by weight; for tilesetters' Use equipment similar to that which is nausea. Wash before eating •grouting procedure, use 2.25 parts available at the Jenny Division,^owder to 1 part Liquid Resin, by Homestead Industries, Coraopolis, PA.veight. Stir the Liquid Resin before to remove wax from the face of the WARRANTY:sing. Empty Liquid Resin into the mix- masonry units or quarry tile. Use 60 psi »»««n<-ii^ i-g vessel. Gradually add the Powder (minimum) steam pressure at the We warrant that our goods will conform-iiie mixing with hoe or trowel until nozzle. to the description contained in the?rtar/grout is uniformly blended to a order, and that we have good title to all-kable consistency. After mixing, PACKAGING. goods sold. WE GIVE NO WARRANTY,

e-25-30 minutes at *3°FT" ™™ ^™mPiaSl™™a WISE, EXPRESS OR IMPLIED,er add Liquid Resin or other ' OTHER THAN AS EXPRESSLY SETarials to mixed material in an at- m CAM i in FORTH HEREIN. We are glad to offer•pt to make the material reusable. v^LtAIM-UP suggestions or to refer you tomove all mixed mortar or grout from All equipment should be cleaned with customers using Sauereisenxmg vessel and mortar pan before acetone, xylene or MEK before No. 21 anH rrimnriimHc inr ° cimi|a

• initial set, removal can be

Estimating Table-material quantities per square foot S aiCommon floor and tank brick quarry tile sizes ___________ _____________ in connection therewith regardless ofLength (in) 8 8 8 8 8 8 8 8 8 8 9 9 9 9 6 6 any of our suggestions as to applicationwidth (in) 3V. 3V. 4 4 4 4 3V, 2V, 4V, 3V. 4V, 4V, sv, 3 6 6 °r construction. In no event shall we be

nl «...v. 1 ,,,.». „, a. 3-,. M. 4V, n3 «, 4V. ,. .,.NO. of Brick with Qur |jafc,j|j_y ancj your exclusive remedyvrin joints 4.43 4.43 4.3 43 43 43 438 7.47 3.83 4.58 3.42 3.42 6.02 s.os - - hereunder or otherwise, in law or inNO. of Brick with equity, shall be expressly limited to ourVvin joints 4.23 4.23 4.n 4.11 4.11 4.11 - - - - - - - - 3.69 3.69 replacement of nonconforming goodsLbs mortar with . . at our factory or, at our sole option, tov,-in side joints repayment of the purchase price ofonly_______0.55 0.64 0.46 0.54 0.63 0.68 1.07 2.54 1.59 2.14 1.02 1.22 2.75 2.41 - - nonconforming goods.Lbs grout with'/4-in joints only 1.04 1.20 .86 1.02 1.18 1.29— — — — — — — — 0.39 0.56Lbs mortar forVj-in setting bed <—————————————————— 1.26 ——————————————————>or back joint only_____________________________________________

bove quantity requirements are based upon 2. Where setting bed or back joint is required, add side' imensions of chemical-resistant masonry units joint material requirements to setting bed or back jointy tile and actual weight of mortar as determined material requirements.C90S. Actual use raw will vary dependent upon

experience o, worKmen. ,ie,d cn- , om n5U\J LJ r::nons and other contingencies. Personnel using the I l_l

above chan should, therefore, add a safety or wastaoe - - -'actor accordingly. * PITTSBURGH. PENNSYLVANIA 15238-2920 USA« -Pi A I •» rt « * PHONE 412/963-C303 • FAX 412/963-7620

March ,989-Supersedes al, previous literature. : 1989 Sauerfti n«7c8,Qn§ Pnnted in USA.

HICCLU HI

O

CtllllllOPLR-180

CD applied under water. Mojg __,___!$ m% RH encountered, hold the mixed____Dry Room -0.136* 50% RH SPEED PLUG in the hand until

it becomes warm. Then rapidlyforce the patch into the hole, and

, . , , , -. USES: SPEED PLUG is used above apply continuous pressure until thec c or below grade, interior or exterior, 4. SURFACE PREPARATION: Cut or SPEED PLUG has set, and the^ __! to stop seepage and flowing water chisel out the concrete or masonry water has stopped running. Do notO O leaks in most concrete and masoftry surrounding the hole or crack, to a Use a twisting motion.° ° walls and floors. The fast initial Set, minimum depth and width of & inch

high strength, and controlled (2 cm). Undercut the crack or hole in 6.3 Floor-Wall Patching: Followexpansion, make SPEED PLUG the the shape of an inverted "V", to make above methods for the specificideal patching material for use in *e bottom of the cut area wider than conditions encountered. Use adams, swimming pools, cisterns. *e top, and to provide mechanical rounded tool to force the SPEEDreservoirs, water tanks, foundations, bond during initial set and final cure. PLUG into the joint, and constructand other structures subject to Flush, blow, or vacuum loose particles, a 45 degree transitional coveleakage. SPEED PLUG will not seal dust, and other foreign material!, from between the floor and wall at therunning water leaks that are caused by the prepared areas. W;t areas, to be same time.thermal or structural movement. patched with potable water before

installing SPEED PLUG. g.4 Exp4Uision/Contractton Cracks:Use SPEED PLUG to stop

__ running water leaks, but do not fill3. COMPOSITION AND MATERIAL: 5 MfVTNr TN«miTirTTnN<5. Phnr cracks completely to the surface.

Quick Setting Hydraulic Cement8 1. DESCRIPTION: SPEED PLUG is Test 6.2 Patching Active Leaks: Start at | ££5 a quick setting hydraulic cement Properties Resuhs Method Remarks the top of the crack or hole, and -< 20 compound used to instantly stop , force the SPEED PLUG to the full g |_

running water or seepage leaks in "™Bile 'JJ?rM depth of the prepared area. Apply § =masonry or concrete. The SPEED Strength C190 ^ ^ pressure to the new patch p.PLUG formulation is nonshrinking, -4 Hour 51° P51 until the SPEED PLUG has taken c

z nonmetalic, and noncorrosiye. ^ Da ''" P5' a firm set. Mix fresh material, and -jQ SPEED PLUG requires only potaj>le -8Day "5 P51 continue patching toward the area ^ ^«5 water for mixing, and achieves initial Expansion/ ASTM 28 Day of the greatest "pressure. When 3 «

set in 1 to 3 minutes, even wljen Shrinkage C157 Test extreme water pressure is •£ O•

(3'8 " 4'3 k£/')< Mlx raPldly Wltn a 7 rnvpUAOF- l nound (045 kel oftrowel to the consistency of stiff putty "• C£ ^ , •JS r JSL nTrrHTVirAT HATA w^ no slump. Mix no more thaV. 30 SPEED PLUG i yields appro matetyl?TECHNICAL DATA seconds. SPEED PLUG will fUsh seta&\,UIIU3. Or£ £*l*r I^lwUVJ will 11,3311 &C1. . , -,f\ • L__ ~C i/ ^f I/

Test m I - 3 minutes. Properly mixed. approximate y 30 inches of K x *g Properties Results Method Remarks SPEEDU PLUG can be hand formed £* c£ck/ 2 cm mck.)3 into a ball.M Compressive ASTM

8 t STSr 1835 psi CI09 6 APPLICATION TECHNIQUES: 8. CLEAN-UP INSTRUCTIONS:co £ 24 Hour 3125 psi ! Dampen areas for repair with ijotable Clean tools and mixing equipment with— 7 Dav 7808 psi water Jmmediately before appliaition of water immediately after use.£ 28 Dal 054? psi SPEED PLUG. Absorb running or•i- ' : standins water.g Fiexural ASTMz o Strength C78 ; 6.1 General Patching: Force SPEED 9. CAUTIONS: Do iwo> 24 Hour 410 psi ! PLUG into the crack or hole by PLUG.i| >. _-" Da> 855 psi ] hand or with a trowel. Rapidly fill Do not apply SPEED PLUG to frozen.< < 2S D* 45 psi i to the full depth of the opening. or frost filled surfaces.

506R-26 MANUAL OF CONCRETE PRACTICE

ation snouid be used for special job requiremen^cr to The particle size distribution of accregates in place willuork to a particular t\pe of shotcrete^irpjcally. be markedly finer than when batcned because the larger

the io»|ing would be specified: ^^ panicles have proponionaiiy larger rebound loss. Table 6. 1type and content ^^ contains typical data for a fine aggregate dry-mix shotcreie

-• Aggreg«e gradation. weight. o Tume . with optimum nozzle velocity and average rebound.' 5) Admixtur^nd dosage

^ A ^ o n t e n T t TABLE 6.1-TYP1CAL CHANGE IN RATIO OFimplified bv spec- CEMENT T0 AGGREGATE PROPORTiONS WITH

" SHOOTING (REFERENCE 7)It is recornrnen^R that arformance specification be Nominal max entering gun | Mix m place

used wheneveKSible. It is alsoTKOmmended that, where ~~possible. tj Mstaller be consulted "o je types of cement, j ' ~'°

4.04.5

I : 5.01 : 6.0

aggrega^rand shotcrete equipment avatle and the shot-cret rfoperties that can be practically acma

6.3—Proportioning of shotcrete mix

3.253.63.84,1

6.3.1 General—Many of the principles of normal con-crete technology can be applied to shotcrete. particularly the 6.3.3.2 Mixture proportions. There is no recognizedwet-mix process. However, differences must be recoenized rational method of designing dry-mix shotcrete proportionsbefore proportioning mixtures. In-pface shotcrete "has a for Stren2tn- Applicators from one geographical area, whohigher cement factor than the design mixture due to re- use lhe same consistent sources of materials, can providebound. Rebound also eliminates a large percentage of adequate proportioning data from prior experience. This•coarse aggregate resulting in finer aggregate in place? This approach is appropriate for many small projects where theeffect plus the fact that"the cemenTcontent of shotcrete cost of Preconstruction testing is prohibitive. Preconstruc-mixtures is usually higher than in conventional concrete, tion testin§ is required if previous data are not available.increases the possibility of shrinkage problems and the de- properties other than strength affect the design criteria, or if

•'.opinem of surface cracking. This situation is less critical design requirements vary from one portion of the work towet-mix shotcrete than in "the dry-mix process. another. Preconstruction testing to determine mixture pro-It is not practical to conduct laboratory trial mixes for the portions is also advisable if there is some question as to the

dry-mix process and there are even problems in duplicating gradation or quality of the aggregate and the effect of theas-shot conditions for wet-mix process. Therefore, field tri~ amount and spacing of the reinforcing steel. ,

1 als and preconstruction testing as described in Section 6.4 II is P°ssible lo produce dry-mix shotcrete of extremelymay be necessary for mixture" qualification. W2h stren§th if high cement contents and quality aggregates :6.3.2 Wei-mix process—Proportioning can basically be are used and if a hiSh de=ree of in'Place compaction is ;

done in accordance with ACI 211.1 with "the aggregate con- achieved. Results to 12.000 psi (80 MPa) compressivetent correction for pumped concrete. """ ~ strength 2 have been reported for trial mix panels andAt times the coarse aggregate content recommended by 10,000 psi (70 MPa) are commonly quoted in the literature.

this proportioning system may be somewhat hiah but aener- Strengths higher than 5000 psi (35 MPa) should not beally the maximum content consistent with placing restraints specified except in carefully controlled projects where re-should be used. search into the potential performance of local materials hasThe slump of the wet-mix process shotcrete should gener- been done>

ally be the minimum that can be handled by the pump. A For coarse aggregate shotcrete mixes. Table 6.2 illustratesslump range of I1/: to 3 in. (40 to 75 mm) is normally some 'Pical data on the effect of cement content onsuitable. Excess slump results in a weaker shotcrete and strength.sloughing when the shotcrete is placed on vertical or over- als are rec!uired to determine the final cement contents.head surfaces. The method of evaluating the strength of shotcrete is de-Wet-mix shotcrete can be air entrained. A range of 5 to 8 uiled in ACI 506-2-

percent of total air at the pump is generally desirable.There will be loss of both slumo and entrained air thrnnoh

the pump. These losses are normally in the order of£o 1* TABLE 6-2-STRENGTH VERSUS CEMENTpercent air and '/: to 1 in (12 to 25 mm) slump, although the ______________FACTQR_____________sjes -,ar> <.vuh length of line. :\Pe of pump, and initial Specified :&-<jav compressoreis of air. Additional entrained air is lost during gunning ______strength ; Cement factor____indicated in Section 2.7.2 " ————'.——:————————:—————;——;——, m.n n i -v r> ft <i6.3.3 Dn-w, process ———PS' ! M* ! lb?d> >gAR 3 178026.3.3.1 Afwae proportion. Aggregates should be ™ ' :j '' ' ™

a blend of sizes as re.quired to produce a combined grading <ooo I ~< e<0-*50 '' w-wwi:.-.:r, :ns limits of Table " 1 —=;—————————— ' ———————————-• ' • Dati is lor u-mci. i inoicrcic mixtures.

Technical Bulletin No. 79-C

Cement-base matrixfor exposed

aggregate panels.DESCRIPTIONThoroseal Bedcote is a waterproof, millmixed, cement-base matrix for exposedaggregate panels.Thoroseal Bedcote isformulated with ingredients which promotesufficient open time and pastiness toaccept the aggregate readily. ThorosealBedcote is suitable for both exterior andinterior application. '

ADVANTAGES• Excellent workability under |the trowel.• Non-shrinking.• Good open time.• Mill mixed for positive control.• Waterproof.

APPLICATIONThe surface must be clean, structurallysound, free of dirt, rust, taitarice, oils, curedand ready to receive the application.Install all the necessary expansionjoints, plaster stops, drip strips, flashings,hangers, fasteners, and other fixedsupports as required prior to applyingThoroseal Bedcote. Lay out the area with"stop beads to insure controllable workingareas. Maximum size of each panel shouldnot exceed 125 sq. ft. (11.6m2).Scratch and brown coats must be at leastVz" (1.27cm) thick or sufficient thickness tolevel masonry surface and hide the joints.Application procedures and compositionmust be in accordance with the recom-mendations of recognized plasteringbureaus and associations.Uniformly apply a heavy brush or rollercoat of Thorobond over the entire surface.This will eliminate suction and porosity,insure a good bond, and allow more opentime for placing stone. Wash stonethoroughly before placing to remove dustand dirt, using a solution of 1 part Acryl60 to 3 parts of water. Allow the stone todry before casting.Mix Thoroseal Bedcote with 1 part Aery! 60to 3 parts water. Apply a tight coat ofThoroseal Bedcote approximately Ve"(3.2mm) thick over the first panel, allowenough time for the material to set, thendouble back with the second trowelcoat half the thickness of the stone to be

APPLYING THOROSEAL BEDCOTE BY TROWEL

Technical Bulletin No. 24-H

Waterproof, cement-basecoating for exterior

below grade concreteand masonry.

can be prepared to last for two hours undernorma| conditions.Thoroseal Foundation Coating is specifically A __. _ . TI^MIdesigned to waterproof the exterior surface of APPLICATIONconcrete and masonry below grade. Normally Thoroughly dampen masonry or concreteapplied with a Thoro Push Broom or Thoroseal surface before applying Thoroseal Foundation6" (15.2 cm) Beaver Brush, it can also be Coating. Do not apply as a thin paint coat. Laymixed with clean washed sand and applied as jt On the wall and level it out. If wall becomesa superior waterproofing parge (trowel dry or mix slarts to pu|| durjng application,applied) coating. Thoroseal Foundation dampen the wall again. Do not thin theCoating is not intended as a decorative finish material.coat.

SPECIFIC APPLICATIONSUSES FOR ORDINARY WATER PRESSURE ORTo waterproof foundations below grade or DAMPNESS IN BLOCK FOUNDATIONS:waterproof back coating between face brick Apply two evenly distributed applications ofand back-up units. Thoroseal Foundation Coating, each minimum

2 Ibs. per sq. yd. (1 kg/mz) or a total of 4 Ibs. perSURFACE PREPARATION sq- vd- <2 k9/m2)-Make sure bothapplications

carry down to and over footer forming a 1 Vz"Surface to be coated must be clean and (3.3 Cm) cove at junction of walls and footer.

isx ^ ^ sfs stsssy INsalts, form oil, laitance, film type curing agents, CONCRETE FOUNDATIONS: Apply oneetc. Clean mortar droppings from top of footer; <**• minimum of 2 Ibs. per sq. yd. (1 kg/m2).form cove at this point with Thoroseal ' Use AcrV' 60 in the mixing water.Foundation Coating mixed to a mortar FOR SEVERE WATER PRESSURE: Brushconsistency. Point and fill all broken corners of on coating using 2 Ibs. per sq. yd. (1 kg/m2).block and breaks in surface. Cut the wires back After 12 hrs., apply trowel coat of minimum 12at least V«" (1.9 cm) and patch with Thorite (or Ibs. per sq. yd. (5.4 kg/m2) or sufficient materialWaterplug). Anchor in place with Waterplug all to bring surface to true and level lines. Forpipes, etc. that pierce foundation walls. trowel applications add 30 Ibs. (13.6 kg) clean

silica sand to each 60 Ibs. (27.2 kg) ofMIXING Thoroseal Foundation Coating. Treatfooteras_ . . . . . . . . described previously in all applications. UsePour dry material mo mixing container or Acryl 60 in the mixing water when application ismortar box, round out center and gradually add '. conrretpclean water to bring to consistency of heavy cuncreie.batter (approximately 2 gallons of water per 60 PARGE COAT: For masonry walls where localIbs: [7.5 liters per 27.2 kgj). (To improve codes require a parging coat. Excellent mix: 30bonding on smooth or dense concrete and lbs- (13-6 kg) clean silica sand to each 60 Ibs.masonry and for all trowel applications, (27-2 k9) of Thoroseal Foundation Coating.prepare a mixing liquid consisting of 1 part uP°n completion of parging coat, brush on aAery 160 to 3 pans of clean water). When power coating of 2 Ibs. per sq. yd. (1 kg/m2).mixing, add material to the water. Stir. Allow FOR FIRMEST BONDING QUALITIES: Add10-15 minutes soaking time to fatten mix and Acryl 60 to the mixing water. Proportions candissolve waterproof pigments for a uniform vary depending on bonding requirements.batcn. When reaay 10 apply, a small amount of Normal proportions are 1 part Acryl 60 to 3water may be added if necessary to bring mix parts clean water (approximately 2 qts. [1.8to batter consistency. liters) of Acryl 60 per 60 Ibs. [27.2 kg]). ForMake sure all powder at bottom of container questionable application^ Q 3t NjFr8sO U

,tiy improveshas been thoroughly mixed to secure a smooth recommended. Acryl 60 Tjrebatch. Stir just before placing. Thoroseal mechanical properties and adhesion toFoundation Coating sets slowly so that enough smooth or dense concrete.

"Engineered Epoxy Systems for Industry'

PRIME-FLEX SERIESPRIME-FLEX 900 LVFLEXIBLE POLYURETHANE INJECTION GiROUT

PRODUCT DESCRIPTION:Prime-Flex 900 LV is a low viscosity water-activateid polyurethane resin which is used

to halt water through cracks and joints in concrete structures. This material can be mixedwith water at a 1 to 1 ratio or utilize the water already contained in the crack or joint.After injection, the Primeflex 900 reacts with the water, expands and forms a flexible foamin the water path.

USES:o Halting Water Flow p Injection Into Hairline Cracks

AREAS OF APPLICATION-o Water Holding Tanks o Dams & Power Plants o Manholes & Sewer Lines O ParkingDecks o Retaining Wajls o Concrete Structures o Waste Water and Sewer Lines

APPLICATION TECHNIQUES -Two methods of injection are possible with Primeflex 900.

1. inject with single component, piston type air, electric, or hand pump and allow toreact with water present in crack or joint.

2. Inject with plural component piston pump adjusted to 1 to 1 water/resin ratb.

For Complete Application Specifications, Contact Prime Resins Technical Support Group.

AR3I7805t

PRIME RESINS, INC.397 Chapman Road / Lithonia (Atlanta), Georgia 30058 / Office: (404) 482-6154 / £ax: (404) 482-6481

DECO-REZSPECIFICATION DATA

EPOXY CHEMICAL RESISTANT SYSTEMSCHEMICAL RESISTANT RESIN

3610

PRODUCT DESCRIPTION & USEDeco-Rez Epoxy Chemical Resistant Systems incorporate 3610, a100% solids two-component epoxy formulation in a variety of chemicaland corrosion resistant applications. These systems provideexcellent acid and alkali resistance in a wide range of applicationsincluding tank linings, coatings for trenches and floors, slurriesfor troweled or sprayed applications on pits, pipes and verticalsurfaces and in self-leveling (Epoxy Trafficote #10) or trowel-applie(TPM #10) flooring systems.

3610 will cure at ambient temperatures as low as 50°P. and has onlya very slight odor during application. It is odorless and tastelesswhen cured and offers excellent resistance to fruit and food acids.

A variety of methods providing highly chemical resistant serviceare available using 3610:

1. As a 100% solids coating for acid and corrosion resistanceincluding tank linings, coatings for concrete floors, trenches,pits and protection on steel or wood.

2. As a binder for self leveling slurry systems and troweled mortarsfor surfacing floors in chemical process plants, metal finishingplants, steel mills, pulp and paper mills, sewage and wastetreatment plants, food processing plants, pharmaceutical plants,textile mills and other plant areas in a wide variety of industriand service conditions.

3. As a binder with specially blended filler for trowel applicationson vertical and over-head areas in trenches, pits, concrete pipeand tunnels. May also be sprayed through special spray equipmentsuch as the Quick Spray Carrousel Pump System.

t

4. As a sealer or glaze coat on a standard epoxy floor system or incombination with silica sand or colored ceramic quartz granulesfor a relatively low cost skid-proof topping.

Advantages;Room temperature curing system as low as 50°F.Can be used in various application methods to achieve an acid andcorrosion resistant surface.

AR3I7806

Limitations;Must be applied to clean, properly prepared surfaces.Substrates must be structurally sound, clean, and dry. Subf.loormust be above 50*F., free from hydrostatic pressure, free frompaint, curing membranes and other foreign material which mayprevent adhesion.The finished appearance of troweled applications may reflect minortroweling irregularities.

TECHNICAL DATAPot Life g 75°F. , minuInitial Set Time (forCuring Temperature LimUltimate Cure 8 75°F.

£ 50°F.Mixing Ratio, by volum

ApplicationCoverage - (Resin Coat

(Mortars)

PERFORMANCE PROPERTIES

REQUIREMENTS

Fungus and BacteriaResistance

tes 45-60 depending on application methodlight traffic 18 - 24 hoursits over SO^F.

5 days14 days

e 2 parts, resin (Part A)1 part hardener (Part B)Depending on method: Spray, Trowel, Roll

ing) 1600 mil ft. per gallon (100% solids)Will depend on amount of aggregate andtroweled thickness.

(CURED BINDER)

TEST METHODS PERFORMANCE

MIL-F-52505 Sec. Will not support growth4.4.2.11 of fungus or bacteria ^^

when subjected to mild«^and bacteria tests ^^specified in TT-P-34.

Impact Resistance

Identation

Resistance to

Taber AbrasionResistance

Water Absorption

Bond Strength to

MIL-D-3134F-Sec. Withstands 16 ft./lbs. no4.7.3 cracking, delamination or

chipping.

MIL-D-3134-Sec. Withstands 2,0000 lbs./4.7.4 sq. in. for 30 min. with-

out indentation.

MIL-D-3134F-Sec. No slip or flow at requiredElevated Temperatures 4.7.5 temperatures of 158

CS17 Wheels with .035 grams loss per 1,0001000 gram load on cycleseach arm for 10,000cycles.

t

ASTM-D-570-63 .15% maximum(24 hrs. immersion)

f

After 7 days water 335 p.s.i. failure inConcrete ; immersion. ACI concrete.

Committee 403,Bulletin 59-43.

C":-2-

A83I78.07

REQUIREMENTS TEST METHODS PERFORMANCE

Flammability ASTM-D-635-63 Self-Extinguishing byThis is determined this test. 'on a sample with abacking similar toconcrete.

Ultimate Tensile ASTM-D-638 5,480Strength (p.s.i.)

Tensil Elongation (%) ASTM-D-638 2.0-3.0

Ultimate Flexural ASTM-D-790 15,290Strength (p.s.i.)

Initial Flexural ASTM-D-790 0.50Modulus (p.si. x .10-5)

Ultimate Compressive ASTM-D-695 14,000-16,000Strength (p.s.i.) I1'

Izod Impact (ft. lbs./in. ASTM-#-256 0.51notch)

Hardness (Shore D) ASTM-D-2240 80

(1) Test Specimen dimensions - 1/2 inch diameter cylinder, 1 inch height(2) Ultimate load occurred at yield.

CHEMICAL RESISTANCE3610 as a Chemical Resistant 100% Solids Epoxy flooring resin system isexcellent in acid and alkali resistance.

CHEMICAL RESISTANCE GUIDEThe following chart is a general guide to the resistance of 3610 epox^resin systems. While this information is reliable, there are manyvariables which must be considered in selecting the proper protectivesystem.

Maximum service temperature of l50eF. unless otherwise noted.

When exposed to ultraviolet light and/or oxidizing agents, the gray,red, green and brown will discolor. This is a surface condition andwill not change other performance properties.

Becau.se many factors such as design, application, exposure, etc. arebeyond the control of General Polymers Corporation, no warranty conce:use of these resins can be made. Whenever possible, a sample should 1tested under actual or simulated use conditions before a final decisi-on the suitability or choice of a given system is made.

— 3 —AR3I7808

KEY: NR - Not Recommended.R - Recommended for continuous contact.I - Recommended for intermittent immersion.S - Recommended for splash and spillage.* - May cause slight stain or discoloration.

Acetic Acid, 25% i R Magnesium Chloride, 50%Acetic Acid, glacial S Magnesium Hydroxide, (Sat.) RAcetone NR Magnesium Sulfate, 50% R*Alum (Sat.) ' R Maleic Acid, 40% to 75*F. IAluminum Chloride, 50% R Methanol to 75°F. sAluminum Nitrate, 50% R Methyl Ethyl Ketone SlightAluminum Sulfate, 50% R SoftenirAmmonium Hydroxide, 50% R Methyl Ethyl Ketone to 75°F. SlightAmmonium Nitrate, 50% R SofteniiAmmonium Sulfate (Sat.) R Milk to 85°F. RAniline to 75°F. I Nickel Nitrate, 50% R*Barium Hydroxide (Sat.) R Nickel Sulfate, 50% R*Barium Sulfide (Sat.) R Nitric Acid, 30% to 75°F. I*Beer R Oleic Acid RBenzene to 75*F. S Oxalic: Acid, 3% RBenzoic Acid, (Sat.) 3% I Phenol, 5% to 80°F. SBenzoyl Chloride to 75°F. R* Phosphoric Acid, 85% SBoric Acid, (Sat.), 30% R Phosphorous Acid, 30% IButyric Acid R* Potasssium Chloride, (Sat.) R*Calcium Chloride, 50% R* Potassium Chlorate, 30% R*Calcium Hydroxide, (Sat.) R Potassium Hydroxide, 50% RCalcium Nitrate, 50% R Potassium Nitrate, 50% RCalcium Sulfate, (Sat.) R* PyridineCarbon Tetrachloride to 75*F. I Salicylic Acid, 3% to 75*F.Chloride Water, (Sat.) to 75*F. R Sodiurit Bicarbonate, 3%Chlorobenzene to 75*F. S Sodium Bichromate, 50% RChloroform NR Sodium Bisulfite, 30% RChromic Acid, 15% S* Sodium Carbonate, 30% RCitric Acid, 20% R Sodium Chloride, 40% RCola syrup to 75°F. R Sodium Chromate, 50% R*Copper Sulfates, 50% R* Sodium Hydroxide, 50% RDichloroethylene NR Sodium Nitrate, 50% R*Ethyl Acetate NR Sodium Sulfate, 50% R*Ethyl Alcohol to 75°F. R Sodium Thiosulfate, 50% R*Ethylene Chloride NR Stannous Chloride, 25% I*Ethylene Glycol R Stearic Acid, (Sat.) RFormaldehyde, 40% R Sugar Solution IFormic Acid NR Sulfuric Acid, 25% SHydrobromic Acid, 47% to 75«F. I* Sulfuric Acid, 30% SHydrochloric Acid, 18% R Sulfuric Acid, 50% SHydrochloric Acid, Cone to 75°F R Sulfuric Acid, 80% to 80°F. S*Hydrogen Peroxide, 30% to 75°F. I Sulfurous Acid IIsopropyl Alcohol to 75°F. R Tannic Acid, 50% IIsopropyl Ether to 75*F. R Tetrachloroethane IJet Fuel Oil to 75°F. R Toluene to 75°F. ILactic Acid, 20% R Trichloroethylene to 75°F. ' SLactic Acid, 85% I Urea, 50% RLead Chloride, (Sat.) R* Xylene to 75°F.

Zinc Chloride, (Sat.) f""" /3R3I7809

GENERAL INFORMATIONINSTALLATION

Workshould be performed only by experienced applicators or'qualifiedshop maintenance personnel. Installation to be performed according tomanufacturer's instructions.

Inspection and preparation of substrate is critical to the applicationof Deco-Rez Epoxy Chemical Resistant Systems. Prepare surfaces forapplication as instructed in "Instructions for Surface PreparationForm G-l". For surfaces not listed, contact our technical department.

Prior to application of Epoxy Trafficote #10, unevenness and surfacedefects should be patched and leveled. Flooring systems shall befinished to specified thickness and free of surface holes and depressi<

AVAILABILITY AND COSTAvailabilityTNormally marketed throughout the United States.

Cost; Depends on job conditions and geographic areas. Available onrequest.

TECHNICAL SERVICESkilled representatives of the General Polymers Corporation areavailable throughout the United States. .Write or telephone direct toGeneral Polymers Corporation for assistance. Literature and installatinformation available on request.

GUARANTEEGeneral Polymers Corporation guarantees 3610 Epoxy Resin to be free ofmanufacturing defects and that 3610 complies with all properties stateabove. General Polymers Corporation will replace any material that donot conform to our standard specifications or will refund the purchaseprice if discovery of non-compliance with specifications is made withione year of delivery of materials.

No representative of General Polymers Corporation has authority tochange or modify our data or our standard warranty in any way or any oprovisions of our standard terms and conditions of sale.

HD-85Rev I

-5-

Material Safety Data Sheet for this product available on request.

IMPORTANT NOTICETHESE PRODUCTS ARE SOLO SUBJECT ONLY TO THE EXPRESS WARRANTIES CONTAINED HEREIN, ADDITIONAL WAR-RANTIES. EXPRESS OR IMPLIED AND ANY WARRANTY OF MERCHANTABILITY IS HEREBY EXCLUO€O.,,»UYfR AGREESTHAT SELLER ASSUMES NO LIABILITY FOR CONSEQUENTIAL DAMAGES Of ANY KIND.WM«C»l (IBWW_fHOM THE USEOR MISUSE Of THE MERCHANDISE SOLO HERCUNOCft. IN-THf tVtWTTOAT THt*««!»vWWW«THAt ANY GOODSRECEIVED DO NOT CONFORM TO THE SPECIFICATIONS AGREED TO BETWEEN THE PARTIES OR IF TH6 BUYER PROVESTHAT SUCH GOODS WERE DEFECTIVELY MANUFACTURED. THE BUYER'S REMEDIES SHALL BE LIMITED TO EITHERTHE RETURN OF THE GOODS AND REPAYMENT OF THE PURCHASE PRICE OR REPLACEMENT OF TH€ NON-CONFORM*ING GOODS AT THE OPTION OF THE SELLER. SUCH REMEDY BEING EXCLUSIVE OF ALL OTHERS AND THE SOLEREMEDY AVAILABLE TO THE BUYER. BUYER HEREBY EXPRESSLY WAIVES ANY CLMM JCL AjOOTTIpNAL DAMAGES.

GENERAL POLYMERS CORPORATION • 9461 U Saint Drlv* * fa Iff !•!<*, Ohio 43014