CORROSION PROTECTION CONCRETE REHABILITATION MECHANICAL ... · Arnold Avenant, from a mechanical and water supply background ... quality control testing of protective coatings is

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CORROSION PROTECTIONCONCRETE REHABILITATION

MECHANICAL REHABILITATIONWATER & SEWER TREATMENT

Corrosion ProtectionSurface Preparations,

Equipment & Coatings (Pty) Ltd.

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COMPANY HISTORY

Established in 1971 S.P.E.C. has undergone a number of changes in name, ownershipand functionality. Hennie Wepener purchased a 50% share in S.P.E.C. in 1995. This was followed by a total buy-out of the company by him in 1996. Hennie was later (1998) joined by Pieter Theunissen and Bennie Matheus, who similarly come from a civil engineering contractingbackground. Arnold Avenant, from a mechanical and water supply background, joined in2000 . Hennie Wepener retired in 2004, selling his shares to the Arnold and Pieter. Pieter van Riet (based in our Cape Town office), from a project management background,joined in 2003. Being with the company since 1997, Xerxes Mwahla became part ofmanagement in 2005. S.PE.C. is focused on its main objective; to provide a specialist corrosion protection and maintenance service to industry. Having available the necessary expertise and quality control management, S.P.E.C. can offer a turnkey solution to all corrosion and maintenance problems. A good workingrelationship has been established with leading consulting engineers and inspectionauthorities in this field. S.P.E.C. is approved as an applicator by the majority of manufacturers and suppliers ofindustrial, marine and offshore protective coatings. All personnel, plant and equipment necessary for the surface preparation, application andquality control testing of protective coatings is available in-house. Apart from work undertaken at our premises in Port Elizabeth and Cape Town, we also render our services on site, throughout Southern Africa.

Corrosion Instituteof South Africa

Sustaining MemberMember

P.O.Box 2986North End6056

19 Kurland RoadPerseverancePort Elizabeth

Tel: 041-463 3670Fax: 041-463 3672

E-Mail: [email protected]: www.spec.co.za



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PLANT RESOURCES





Tel: 041-463 3670Fax: 041-463 3672


In addition to it’s fixed facilities at the Perseverance and Blackheath premises, SPEC has the following mobile equipment available for on-site work:

• Compressors:– 600 cfm Electric - 160A 380V (1)– 400 cfm Electric - 120A 380V (2)– 250 cfm Electric - 70A 380V (2)– 600 cfm Diesel (2)– 250 cfm Diesel (2)– 30 cfm Electric - 25A 380V– 25 cfm Electric - 20A 380V– 12 cfm Electric - 16A 230V (2)

• High Pressure Washers:– 400Bar/40 lit/min - Diesel– 350Bar/37 lit/min - Diesel– 250Bar/32 lit/min - Electric 30A 380V– 150Bar/15 lit/min - Petrol – 150Bar/11 lit/min – Electric 16A 230V– 130Bar/11 lit/min - Electric 16A 230V – 110Bar/11 lit/min - Electric 16A 380V

Hot Water 70C• Crane Trucks – 14 & 8 ton• Fork Lifts

– 3.5 ton (2)– 2 ton

• Storage/offices– Mobile Offices (10m x 3m) (2)– Container office (1)– Steel containers (5)

• Scaffold– Swing - Electric 16A 230V– Standards, ledgers, boards, wheels etc

• Concrete Mixers – 330lit Tilt Diesel (2)– 175lit petrol (1)

• Pumps– submersible 50mm & 32– 6” Centrifugal diesel– 6” Centrifugal electric 30A/380V– Various water pumps

• Winches 380V 1ton - 3 ton• Large range of pneumatic and electrical tools



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SURFACE PREPARATION

SPEC offers the following surface preparation methods:

• Degreasing and neutralising– Steam Cleaning– High Pressure Washing and removal

of surface contaminants and loose coatings

• Abrasive blast cleaning to all ISO standards

– using all media types:• Platinum Slag (Blastrite)• Steel Grit• Glass Bead• Aluminium Oxide• Plastic Bead• Garnet (Microblast)• Sodium Bicarbonate

(Sodabrade)– Wet or dry blast cleaning

• Needle descaling and chipping

• Power grinding and brushing

• Control testing undertaken:– Climatic (Temperature, Relative

Humidity & Dewpoint)– Surface Profile (Digital Elcometer)– Cleanliness (Tape)– Salt Contamination (Webber-Reilly)

Blast cleaning of chill-water tank using platinum slag

Client: Cadbury’s

Blasting Cabinet for Aluminium Oxide,Glass & Plastic bead media.





Tel: 041-463 3670Fax: 041-463 3672




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COATINGS & LININGS

SPEC offers the following coating and lining applications using conventional, airless and twin component spraying techniques:

• Epoxies and Urethanes– Tank & Pipe Linings:

• Chemical Resistant• Petroleum & Solvent Resistant• Food Grade• Potable Water• Hot Water

– Coatings• As for above, also• Structural steel• Machines and equipment• Industrial floors• Chemical Bunds

• Elastomeric Polyurethane– Tank linings– Pallet and dunnage lining– Load body Liners (not commercial)– Protective Covers– Flexible Moulds

• Glass Flake & Ceramic Coatings and Linings– Severe corrosive environments– Pump rebuilding– Valve rebuilding


Humidity & Dewpoint)– Wet Film Thickness– Dry Film Thickness (Magnetic

Elcometer)– Adhesion Testing– Continuity Testing (Wet Sponge and

Holiday Testing)

Classic SchoonerClient: Welfit Oddy

De Beer’s Mining -Diamond Dredge Pipes

Client: Algoa Oil & Pipeline Services

Churchill Dam - Clarifier / FloculatorClient: City Engineer’s - Port Elizabeth

ValvesClient: Northfield

Engineering

20mm Polyurethane

Elastomer lining to extractor fan cowl





Tel: 041-463 3670Fax: 041-463 3672




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INDUSTRIAL PAINTING - MASTS & ELEVATED STRUCTURES

SPEC is experienced in the industrial painting of masts and other elevated structures:

• Equipment:• Electric winches 380V

– 1 ton– 0.5 ton

• Electric “Sky Climber” suspended scaffolds 220V

• Manually operated suspended scaffolds

• Custom built scaffolds





Tel: 041-463 3670Fax: 041-463 3672


Lattice Mast 55m OudtshoornClient: Vodacom Southern Region

Sectional Pole Mast George 55mClient: Vodacom Southern Region

Special Mast 55m Jeffrey’s BayClient: Vodacom Southern Region



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VALVES & PUMPS

SPEC offers a full pump and valve component rebuild service at a fraction of replacement cost.

• Rebuilding of worn and corroded

– Pumps• Impellers• Volutes• Casings

– Valves• Casings• Flanges• Seats• Gates• Butterflies

– Heat Exchangers

• Elastomeric Polyurethane– Sand & Slurry linings– Hopper Linings

• Glass Flake & Ceramic– Chemical resistant– Abrasion resistant– >160°C

• Control testing undertaken:– Third party pressure test certificates if

required





Tel: 041-463 3670Fax: 041-463 3672


Churchill Dam - Modular Valves before rebuildClient: City Engineer’s - Port Elizabeth

Multistage Pump during rebuildClient: Sappi Boskor

Coating to 2mØ x 12m Archimedes Screw PumpClient: Biwater / PEM



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POWDER COATING: RILSAN / FBE®

SPEC is an approved applicator of RILSAN® nylon powder coating and FBE (Fusion Bonded Epoxy)

The coating is applied using the electrostatic method and gives a seamless coating between 300µm and 500µm thick. It is applied to any metallic object which will accept pre-heat treatment of 250°C.

Available facilities:Ovens: 1.5m x 1.8m x 2m and other smaller onesElectrostatic spray equipment

Applications:• Corrosion protection• Abrasion protection• Chemical resistance• Petrochemical industry• Electrical insulation

Internationally used to protect pumps, valves, pipe fittings, automotive components, food and beverage equipment, etc.

Certified for use in contact with food and potable water.

Withstands cathodic disbondment.


Humidity & Dewpoint)– Dry Film Thickness (Magnetic

Elcometer)– Continuity Testing (Wet Sponge and

Holiday Testing)

Rilsan coated tee piece

Valves require complete stripping

prior to coating withRilsan.





Tel: 041-463 3670Fax: 041-463 3672




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MECHANICAL MAINTENANCE

SPEC offers their services in the fields of water and sewer related mechanical installations and refurbishment.

• Rebuilding of worn and corroded

– Pumps

– Valves

– Aerators

– Mixers

– Scrapers

– Gearboxes

– Biological Distributors

– Gravity Filter Systems

• Rebuilding of worn shafts using hi-tech ceramic and metal filled epoxies, such as Belzona products.

• Control testing undertaken:– Third party pressure test certificates

if required

Sludge scraper and stilling drum before rehabilitationClient: Graaff-Reinet Municipality

Digester mixer after refurbishmentClient: Graaff-Reinet Municipality

Horizontal split casing pumps before and after rehabilitationClient: Graaff-Reinet Municipality





Tel: 041-463 3670Fax: 041-463 3672




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REFURBISHMENT ON BULK WATER SUPPLY SYSTEMS

SPEC did/does mechanical refurbishment to DWAF equipment on various dams in the Eastern and Western Cape regions (2 year maintenance contracts:

Western Cape – current (total value of contract per year to be +-R6m :

– Bulshoek dam installation of 16 big sluice gates (6m*8m)and the corrosion protection to the lifting structures.

– Voelvlei dam installation of sleeve valve with pipe work inside outlet tower.

– 24 Riviere canal system – repair, blasting and coating 2 off buoyancy gates. Manufacture new sluice gate and install with hydraulics.

– Jonkershoek shaft (60m deep) –repair landings and waterproof tower

– Theewaterskloof dam – build sluice, repair valves, coatings to various pipes and valves.

– Brandvlei dam – remove, repair, corrosion protect 2 off radial gates for Holsloot canal intake works.

– Clanwilliam dam – coredrill on top of dam for bracket installation, install new gates and repair 2 off outlet houses (concrete works). Install storage facilities for emergency gate on top of dam wall.

Bulshoek dam – openings for sluice gates underneath and top structure from steel

Voelvlei dam (24 Riviere canal system) –Intake buoyant radial gates – before and

after corrosion protection

Voelvlei dam (24 Riviere canal system) –Intake sluice gates (3 off) – half of gate in workshop with ‘stripe coat’ on it, hydraulic

system connected to wall on site





Tel: 041-463 3670Fax: 041-463 3672




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REFURBISHMENT ON BULK WATER SUPPLY SYSTEMS

Eastern Cape 2001 – 2003 (total value of contract was R14m over 2 years)

– Umtata dam – excavate 6m deep and replace a broken steel pipe (1.6m) leading from the dam to the town, build manhole chamber and drainage layers. Design, manufacture and install a s/s sluice gate. Remove, refurbish, blast & coat and re-install stack-pipe in outlet tower.

– Lubisi dam – remove 36” and 42” gate valves, refurbish/repair, corrosion protect and re-install. Do crack injection in inlet tower. Build new walkways, refurbish sleeve valves and install new butterfly valves

– Waterdown dam where both 1m diam outlet pipes to a total length of 140m were Denso wrapped

– Laing dam – Remove, refurbish, rebuild, install and coating of dual scour outlet pipe system

– Katrivier dam – Refurbish emergency gate, crane and corrosion protect. Remove, refurbish, rebuild, install and coating of dual outlet pipe system with sleeve valves.

– Kouga dam – Remove, reurbish & re-install 2 off hydraulic cylinders (2.7 tons each) from the dam crest. Break out old scour 42” spherical valve and replace it with new knife gate valve. Replace all pipe work and corrosion protect. Install all required hydraulic equipment to operate knife gate valve.

Katrivier dam – repairs to sluice gate and pipes after completion

Kouga dam – transport hydraulic cylinder down dam slope and outlet structure where new 1.4m knife gate was installed

Umtata dam – Installation of 1.6m diam pipe and building of manhole system. Installation of stack pipes inside outlet tower.

Lubisi dam – installation of the rebuilded 42” gate valve and also the sleeve valves before and after refurbishment





Tel: 041-463 3670Fax: 041-463 3672




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CONCRETE PROTECTION AND REHABILITATION

SPEC offers a complete concrete protection, water proofing and rehabilitation service.

Protection of concrete against:– water penetration– chloride penetration– carbonation– chemical attack

• Application areas:– Sewer pump stations and sumps, concrete

sewer pipes, etc..– Chemical spillage containment (bunds).– Floors– Low reinforcing cover– Damaged structures

Rehabilitation of damaged concrete:– Repairs to spalling and cracking due to

corrosion of the reinforcement.– External reinforcing by means of steel

plates or carbon fibre strips.– Drilling and grouting in of additional

reinforcing bars or post tensioning bars.– Crack injection and sealing.– Polymer and epoxy repair mortars.– Migrating corrosion inhibitors.


Humidity & Dewpoint)– Dry Film Thickness (Destructive)– Compressive strength (Cube and core

tests)

Crack injection of wall and corrosion protection of sluice gate - Churchill Dam

Client: PEM City Engineer’s

Sulfate attack: Anaerobic digesterClient: Graaff Reinet Municipality





Tel: 041-463 3670Fax: 041-463 3672




SPECIALIST DEMOLITION WORK

SPEC has experience in technically difficult and potentially dangerous demolition work.

Contracts undertaken to date include:

PEM: Fishwater Flats Reclamation WorksFS Building

• Removal of 120 no. 3 ton pre-cast / post tensioned cladding beams from a height of 18m

• The beams had become a danger due to the advanced stage of reinforcement corrosion and concrete spalling

DRC De Duin - Humewood: Church Spire

• Removal of 75 tons of cast in situ reinforced concrete forming the church spire at a height of 32m

• The spire had become a danger due to the advanced stage of reinforcement corrosion and concrete spalling

Demolition of spireClient: DRC De Duin - Humewood

Removal of cladding: Fishwater FlatsClient: Port Elizabeth Municipality

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Tel: 041-463 3670Fax: 041-463 3672




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REFERENCE LIST

Person Company Telephone

Greg TuckerThomas JachensBrendan Theunissen (Cape Town)

Ninham Shand (East) – Consulting Engineers

041-581 3310

Chris Dickson Stewart Scott (East)- Consulting Engineers

041-373 9300

Mike HammondDup van ReenenClive Davey

AfriCoast Engineers 041 505 8000

Markus Niemand GOBA Consulting Engineers 082 787 9976

Andre DyerJohan Killian

Amatola Water Board 08332052610826584102

Peter Barry DWAF – King William’s Town 083 627 5930

Wally Kohlmeyer DWAF – Pretoria 012-336 8021

Thys Fourie DWAF – Worcester 023-348 5600

Johan JoubertEngineer-in-Charge: SewerageDave RaymerEngineer-in-Charge: Water

NMMMPort Elizabeth City Engineer's

041-506 2911

Mike MurrayLes van Staden

NMMM – Harrower Road 041 373 7641

Gavin McClelandBarry Gifford

ROV Durrant Engineering (Pty) Ltd 041 453 2530

Frans Viljoen Sigma MPC Coatings 0828070572

Andre Barnard Sika 0824909107





Tel: 041-463 3670Fax: 041-463 3672


Documents

CORROSION PROTECTION CONCRETE REHABILITATION MECHANICAL ... · Arnold Avenant, from a mechanical and water supply background ... quality control testing of protective coatings is