SECTION 9

CORROSION PROTECTION AND ODOR CONTROL

9.1 MATERIALS

9.1.1 Corrosive Environments

Corrosion protection systems and surface coatings shall in all cases be suitable
for exposure to their contact with environmental conditions which may include
any or all of the following :-

(1) The climatic conditions prevailing in the project area with particular
emphasis on temperature variations, high surface temperatures and high
humidities.

(2) Septic sewage with a pH value of less than one.

(3) Sulfuric acid solution in sewage slimes in concentrations up to 15 % by

weight.

(4) Hydrogen sulfide and other gases emanating from sewage, septic sewage
and sewage sludges.

(5) Saline groundwater with high chloride or sulphate contents both below
the water table and in soil zones above the water table where capillary
action and the presence of oxygen may cause extremely severe
conditions.

(6) Wind blown chlorides.

(7) Wind blown abrasive sands.

9.1.2 Paint

Protective and decorative paint systems including primers and undercoats shall
be obtained ready mixed for use. All containers of paints and other coating
systems shall show date of manufacture, shelf life and pot life where
applicable. Paint shall be applied as per Clause 9.2.2 (refer to Clause 19.4 for
schedules of protective coatings and surface preparations).

The Contractor shall only be allowed to use paints which are delivered to the
site in sealed cans or drums bearing the name of the manufacturer and properly
labeled.

Tints and shades of final coats shall be advised by the Engineer or his
Representative.

9.1.3 Impervious Tanking Membrane

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Membrane used for tanking to concrete structures shall be impervious, self-

adhesive and covered with a release agent.

Rubber bitumen/PVC membrane shall have a minimum bitumen thickness of

2.0 mm and PVC thickness of 0.3 mm.

9.1.4 PVC Sheet Lining Materials

PVC sheet materials to be used for lining concrete structures and pipelines
internally shall be manufactured from polyvinyl chloride, plasticisers and
pigments to make permanently flexible sheets.

The colour of the sheet shall be approved on site.

The PVC sheet shall have a minimum thickness of 1.5 mm and shall be formed
by extrusion to have on one side locking keys or ribs of either ‘T’ or diamond
section at centers not greater than 75 mm. It shall be capable of forming a
continuous 100% effective seal with the use of welding strips or other
approved method and shall be supplied with all materials and tools for making
the joints.

The tensile strength of the material shall be not less than 17000 kN/m2.

All weld strips, patches and other sheets used in the permanent fixing of the
ribbed sheet shall be of a material having the same composition as the ribbed
sheet.

9.1.5 Reinforced Plastic Liners

Reinforced plastic liners to be used for lining pumping stations and manholes
shall be manufactured (as per Clause 19.1.4) to the dimensions given on the
Drawings, within the following tolerances :-

(1) The work size, which is defined as the internal diameter as specified by
the manufacturer, shall be declared and shall not differ from the normal
diameter by more than ± 1%.

A manufacturing tolerance on the work size of 10 mm will be allowed

provided that a tight fit is achieved between the liner and the slab liner.

(2) Liners shall be supplied in lengths to suit requirements with a resin-rich

finish to internal surfaces.

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(3) Minimum thickness shall be 7 mm for sewerage work and 5 mm where

approved for drainage work.

(4) The out of squareness shall not be greater than 10 mm.

(5) The deviation from straightness of the bore of the liner shall not exceed
20 mm.

Although the liners are not designed to be structural, they shall have a
sufficient stiffness to withstand :-

(1) Buckling or distortion in transit or storage.

(2) A hydrostatic head of 8 metres without distortion damage, leakage or

permeation.

(3) Grouting pressures.

Prior to grouting of the manhole liner at least 24 hours shall be allowed for
temperature equalization between the manhole structure and the reinforced
plastic liner.

The manufacturer shall provide shop drawings of the proposed top slab liners
prior to manufacture for approval.

The manufacturer shall stipulate the maximum deflection of the slab liner
permitted without causing surface cracking to the gel coat. The Contractor
must take care not to exceed this limit, and any surface cracking that occurs
will be repaired.

9.1.6 In-Situ Laminations

The Contractor shall apply either of the following systems of laminations to

renovate the manholes:

(1) Epoxy resin mortars and laminating systems.

(2) Lamination using glass chopped strand mats impregnated with

isophthalic resin and with vinylester resin.

(3) Bisphenol polyester resin with heavy duty glass cloth inclusion.

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Epoxy Resin System

A mortar consisting of an epoxy resin and hardener shall be mixed with a filler
material to produce a thixotropic dense trowel suited mix.

The mortar shall be manually applied to all internal surfaces and left at least
15 minutes.

A minimum of 7 mm of GRP laminate shall then be applied in two layers. The

benching laminate shall be sealed on to the in-situ channel liner with an
approved compatible material. The top surface of the benching shall be treated
to produce a non-slip finish.

Isophthalic and Vinylester Resin System

Firstly the surface of the manhole walls and the surface of the cover slab soft,
benching and channel (concrete) shall be coated with isophthalic resin.

Three layers of 600 gm/m2 glass chopped strand mat shall then be applied and
impregnated with isophthalic resin to provide an approximate thickness of 5
mm.

Next one layer of 600 gm/m2 and one layer of 300 gm/m2 glass chopped strand
mat shall be applied and impregnated with vinylester resin.

Following this two layers of glass veil shall be applied and impregnated with
vinylester resin.

Finally a coating of vinylester resin with paraffin wax shall be applied to

provide a total minimum thickness of 7 mm.

Bisphenol Polyester Resin with Heavy Duty Glass Cloth Inclusion System

All cleaned surfaces shall be primed with a polyester based primer to seal the
surface and aid the application of the lining.

The base coat of resin reinforced with filler shall be trowel applied to
approximately 1.5 mm thick. The reinforcing cloth shall be consolidated into
the first trowel coat with particular attention being paid to ensure that the cloth
is fully wetted out. This application shall be allowed to cure overnight before
applying the top coat of resin. This resin reinforced with the same filler shall
be troweled on and dressed with a rolling aid.

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9.1.7 Epoxy Mortar

Where indicated on the drawings or specified to use epoxy mortar for

benching and channels in any manhole or any other structure such as
chambers, pump station wet-well, etc., they shall be formed to have a min. of
10 mm thickness of an approved epoxy-resin mortar system.

The epoxy mortar system shall be a trowellable, two component epoxy resin
system consisting of a prefilled base and unfilled reactor which when mixed
shall produce a high strength, impermeable and chemically resistant mortar.

The epoxy mortar system shall have excellent chemical resistance to sodium
chloride and sulphuric acid (shall pass the relevant chemical resistence test),
and shall have high impact resistance. Typical properties are given in the
following table:

Table 3-7. Properties of Two Component Epoxy Mortar

Property Test Method Limit

Sag at 10 mm thickness - None

Working Time ASTM C308 > 90 min. at 25°C
Full Cure at 25°C - 3 to 7 days
Setting Time at 25°C - 30 to 45 min.
Water Absorption ASTM C413 < 0.07 %
Compressive Strength BS 6319:Part 2 > 40 N/mm2 at 25°C,
7 days cure
Flexural Strength BS 6319:Part 3 > 3 N/mm2 at 25°C,
7 days cure
Tensile Strength BS 6319:Part 7 > 8 N/mm2
Bond Strength BS 6319:Part 4 > 30 N/mm2
Density BS 6319:Part 1 1750 kg/m3

When placed on a concrete substrate the epoxy mortar system shall have an
adhesive strength of not less than the internal cohesive strength of concrete.

To achieve the necessary adhesion to the substrate an epoxy primer compatible

for use with the mortar and the substrate shall be applied.

The epoxy mortar, or the primer where required, shall be suitable for application
onto a substrate with a moisture content of 4% or less as measured by the
"wet-check" Moisture Meter or other instruments approved by the Engineer.
The pot-life of the mixed mortar shall not be less than one hour at the
temperature at the place of application at the time of mixing. The Engineer may

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restrict application to such time as the ambient temperature is sufficiently low

for the specified pot-life to be ensured.

There shall be strict control of surface cleanliness between primer and epoxy
mortar and between coats of the same. Vacuum removal of dust and sand shall
be employed and water soluble contamination shall be removed as specified
above. Where dirt or dust has become trapped in the primed surface it shall be
removed with suitable abrasive paper. The surface being primed shall be free of
visible moisture throughout these operations.

The mortar manufacturer shall stipulate primer and epoxy re-coat intervals for
all curing temperatures likely to be encountered and these shall be adopted with
a maximum tolerance of +4 hours. Where this is exceeded the surfaces to be
re-coated shall be suitably abraded to remove gloss.

Mixing of the components shall be strictly in accordance with the

Manufacturer's recommendations and care shall be taken to avoid the
entrainment of air in the mixes.

Wet thickness gauge shall be used by the mortar applicators continually to

check that sufficient mortar is being applied to achieve the required dry
thickness.

9.1.8 Bituminous Emulsion

Bituminous emulsion shall be to the approved standard and shall not contain
less than 53 % of bitumen.

9.1.9 Waterproof Paper

Waterproof building paper shall be to the approved standard. For roadworks it

shall be Class B.

9.1.10 Protective Materials for Wrapping Pipeline Components

The protective materials for wrapping pipeline components shall comprise a

rust inhibiting compound for the bolts, a mastic or comparable filler which
will not harden for moulding over the assembly, and a waterproof tape for
wrapping.

9.1.11 Approved Paint Suppliers

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CORROSION PROTECTION AND ODOR CONTROL

The following paint systems have been successfully used in sewage

environments in Dubai. Reference to these systems in no way precludes the
use of similar or superior systems by other suppliers.

Supplier Paint System

1. Colebrand Limited Epoxy Prefabrication Primer: CXL 100.

Colebrand House Epoxy Resin Solvent Free Coating : CXL 115.
20 Warwick Street High Build Epoxy Airless Spray Coatings.
Regent Street CXL 141 for temperate climates applications.
London WIR 6BE CXL 140 for hot climates applications.
England

2. Corroless International Limited Corroless T.

Berk House, Basings View Corroless Epoxy.
Basingstoke
Hampshire RG 21 2HW
England

9.2 INSTALLATION OF PROTECTIVE COATINGS AND LINERS TO

CONCRETE

9.2.1 General

Concrete structures shall be protected both internally and externally where

indicated on the Drawings and by the methods detailed.

9.2.2 Protective Coatings/PVC Liners

All protection systems shall be applied strictly in accordance with the

manufacturer's instructions, two copies of which shall be included with the
Contractor's application for the approval of the material, and when approved
will be deemed to be part of this specification unless stated otherwise.

The permissible rate of permeation of all protection systems shall not exceed
0.0027 per inches (ASTM, 1 per inch = 1 gramme of water per hour per square
foot (0.0929 m2) per mil (0.0254 mm) of thickness for a 1 inch (25.4 mm)
difference in Hg vapour pressure on each side of a membrane.

Coatings shall not be applied at expansion, contraction or construction joints

which incorporate a sealant.

(1) External Buried Surfaces

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The external surfaces of concrete substructures shall be protected or "tanked"

by one of the following methods which will be indicated on the Drawings.

a) An approved impervious bituminous waterproof membrane:

The membrane shall be tropical grade, cross laminated to have high tear
strength; and puncture and impact resistance and shall be chemically
resistant for protection against aggressive soils and contaminated
groundwater.

The membrane shall comply with the following :-

Property Test Method Typical Results

2
Tape Strength ASTM D638 Long 4.2 N/mm2
Trans 4.8 N/mm2

Tensile Strength ASTM D638 Long 42 N/mm2

Trans 48 N/mm2

Elongation Film ASTM D638 Long 210 %

Trans 160 %
2
Tear Resistance ASTM D1004 Long 340 N/mm22
Trans 310 N/mm2

Adhesion to Self Concrete ASTM D1000 1.8 N/mm2

2
Puncture Resistance ASTM E154 220 N 65 mm2
Water Resistance : ASTM D570
After 24 hours 0.14 %
After 35 days 0.95 %
Environmental Resistance ASTM D543 Conforms
2
Moisture Vapour ASTM E96 0.3 g/m2 /24 hrs.
Transmission Rate

The membrane shall be laid on to smooth concrete blinding surface free

from sharp edges and projections and on to walls primed with an approved
primer and applying the performed membrane, sticky side downwards, laid
strictly in accordance with the manufacturer's instructions. The minimum
over laps shall be 50 mm side and end.
During the backfilling operation around all tanked structures, the
waterproof membrane shall be protected from damage by the use of an
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approved protection board. The board shall be manufactured from graded

and selected kork granules bound with modified bitumen and encased
between two layers of tough asphalt paper. The board shall be light weight
and capable of providing protection against abrasive backfilling. The board
may be stored outside, but shall be kept flat on original pallets.

b) A brush applied bituminous emulsion:

The surface shall first be wire brushed and all dust and loose scale
removed. Three coats of bituminous rubber emulsion paint shall then be
applied. The second coat shall not be the same colour as either the 1st or
3rd.

Both methods of protection shall totally enclose the substructure within a

waterproof membrane to the limits shown on the Drawings.

(2) Internal and External Exposed Surfaces

Where exposed surfaces of concrete structures are not protected by reinforced

plastic liners one of the following systems will be indicated on the Drawings
where required.

a) An epoxy resin, acrylic, polyester or latex paint system:

The surface shall first be wire brushed and all dust and loose scale
removed (refer to Clause 19.4 for schedule of surface preparations). An
epoxy resin or other primer/sealer (for concrete and allied substrates)
shall then be applied followed by coats of high build epoxy airless spray
or other coatings to give a minimum dry film thickness (dft) of 300
microns. Freedom from pinholes shall be established by use of a spark
tester. The approved paint system must have adequate flexibility to suit
the thermal movements of the concrete without cracking whilst
maintaining an effective bond.

b) A PVC sheet lining system :

The PVC sheet lining shall be fixed such that the keys or ribs are cast
into the concrete surface. The lining shall be capable of taking up the
same profile as the concrete substrate as indicated on the Drawings.

Site operatives for employment on this work shall be certified by the

manufacturer as trained to a satisfactory standard in fixing and welding
techniques.

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After completion of either of the linings or systems as described in sub-

clauses (a) and (b) above they shall be offered for inspection and testing.
Two sets of testing equipment, e.g. feeler probes and spark testing, shall be
provided and be maintained and available at all times for the sole use of the
Engineer's Representatives.

Only linings or systems completely free from pinholes will be accepted.

9.2.3 Reinforced Plastic Liners

The construction methods employed shall be so as to ensure that a

completely water and gastight seal is made preventing any exposure of the
concrete surround to the corrosive liquids and gases present as detailed
below and in Clauses 15.5.4 and 15.5.5.

In particular:-

Reinforced plastic liners shall be handled in the same manner as reinforced

plastic pipes. In addition, extra care shall be taken to avoid damage to the
liners which are not designed to carry loads.

The manufacturer shall visit the site to demonstrate to the Contractor in the
presence of the Engineer's Representative the methods of handling and
lifting, including formation of the joints between the chamber liner.

The Contractor is reminded that these liners are not designed to withstand
pressure exerted by the concrete during construction.

9.2.4 Cutting and Sealing of Reinforced Liners

Where the Contractor is required for any reason to cut reinforced plastic
liners, he shall seal the exposed ends with an approved resin before
incorporating the cut reinforced plastic in the work. No cut reinforced plastic
shall be used until the resin has cured.

The resin shall be as recommended by the manufacturer of the reinforced

plastic item and shall be pigmented so that the areas where it has been
applied are easily identifiable.

It shall be delivered to site in sealed containers bearing the name of the

manufacturer and properly labelled as to its content and shelf life.

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9.3 ODOR CONTROL FACILITIES

9.3.1 General

The Contractor shall provide the labor, materials and equipment necessary to
install and test the odor control facilities as shown on the Contract Drawings
and as specified herein. The odor control units shall be either of the
activated carbon filter types or of the natural soil filter bed types as indicated
in the Drawings.

9.3.2 Soil Moisture and pH Probes

Moisture and pH probes shall be able to continuously measure percent

moisture and pH in the soil. All components shall be highly resistant to
corrosion due to sewage and very high concentration of hydrogen sulfide and
other gases. Soil moisture probes shall measure moisture on a percentage
basis in the full range of soil moisture (0-100 percent). pH probes shall at a
minimum be accurate within the 4-10 standard unit range. All probes shall be
designed for maintenance and replacement with minimum soil disturbance.

9.3.3 Activated Carbon Odor Control Filter

The activated carbon odor control filter shall be furnished and installed in
accordance with Clause 17.2.48. The air blowers for the odor control unit
shall be as specified in Clause 17.2.17.

9.3.4 Natural Soil Odor Control Filter

9.3.4.1 Materials

HDPE (High Density Polyethylene) Liner

The HDPE liner shall be furnished and installed in accordance with Clauses
19.3.4 and 19.2.13 and as shown on the Contract Drawings.

Washed Stone

Stone for the air plenum shall be washed, rounded, uncrushed, well graded in
size from 20 mm to 25 mm and consisting of clean, and durable particles free
from dirt, vegetation or other objectionable matter and free from an excess of

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soft, thin elongated, laminated or disintegrated pieces. The Contractor shall

submit a sample of the stone to the Engineer for approval prior to placement.

Wood Chips

Wood chips shall be obtainefrom hardwood and shall be of 10 mm to 50 mm

diameter. Not more than 2 percent shall consist of leaves, twigs or shavings.
They shall be free of extraneous materials, stone and debris. The Contractor
shall submit a wood chip sample to the Engineer for approval prior to
placement.

Soil Filter

The soil filter shall be a mixture of approved natural sand or sandy loam and
treated compost. The compacted soil/compost mix shall have a 50 percent
porosity. The compost shall be a product of thermophilic aerobic
stabilization. It shall be adequately stabilized, so as to be completely free of
any odors. The compost shall be friable, pass through a 13 mm mesh screen,
and be free of stones, stocks and all objectionable debris. Compost shall have
a pH of 5.5 to 8.0 and no less than 25 percent volatile solids. The compost
source is subject to the review of the Engineer. All compost shall be "cured"
to the point that it is no longer self heating.

9.3.4.2 Installation

The Contractor shall place the stone, wood chips, soil and compost in layers
of uniform thickness as indicated on the Contract Drawing(s) or as directed
by the Engineer. The stone, wood ships, soil and compost shall be placed so
as not to damage the aeration piping. Damaged piping is to be replaced by
the Contractor at no additional cost to the owner.

9.3.4.3 Monitoring

The Contractor shall perform the following selected soil and atmospheric
analyses at the direction of the Engineer, but not more than once per week
with the exception of soil moisture and pH, for the length of the natural soil
filter maintenance period. The results of the analyses shall be recorded and
presented to the Engineer at the end of each month. Soil samples must be
taken so as not to disrupt the even distribution of air through the odor control
filter.

Atmospheric Hydrogen Sulfide

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Hydrogen sulfide (H2S) gas concentrations shall be measured in the

atmosphere directly over the filter bed with a probe placed immediately
above the surface of the natural soil filter. The H2S levels shall be monitored
and recorded continuously.

Soil Moisture and pH

Soil moisture and pH shall be monitored and recorded continuously at a

depth of 0.75 meters from the natural soil filter surface using the soil
moisture and pH probes as specified in Clause 9.3.2.

Chlorides, Sulfides and Biological Analysis

Chloride and sulfide concentration shall be measured from soil sample

collected at a depth of approximately 0.75 meter from the natural soil filter
surface. A biological analysis shall be performed on the same soil samples to
identify biological organism in the filter media. The samples for these
analyses shall be taken once per month unless otherwise directed by the
Engineer.

9.3.4.4 Maintenance

Where excessive settling or discontinuities have occurred in the soil filter

media, the Contractor shall replace the entire soil/compost media or add
additional soil/compost mixture at the direction of the Engineer.

9.3.4.5 Acceptance Test

The Contractor shall test the porosity of the compacted soil/compost mixture
before placement and provide the results of the test to the Engineer.

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