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Selecting and Sourcing Coating Systems for Water Tanks A JPCL eBook

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Page 1: Selecting and Sourcing Coating Systems for Water  · PDF fileSelecting and Sourcing Coating Systems for Water Tanks A JPCL eBook

Selecting and SourcingCoating Systems for Water Tanks

A JPCL eBook

Page 2: Selecting and Sourcing Coating Systems for Water  · PDF fileSelecting and Sourcing Coating Systems for Water Tanks A JPCL eBook

Selecting and SourcingCoating Systems forWater TanksA JPCL eBook

Copyright 2011 byTechnology Publishing Company2100 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.

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Introduction iii

Performance or Preference: A Look at 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

Contents

ii

1

7

Contents

12

20

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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 alpha-

betical 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.

Introduction

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hile water storage tanks may vary greatly in size, style, and design,all share a common need for maintenance or periodic recondition-ing. Concrete tank exteriors, for example, are regularly protectedwith 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 systemsrepresent common areas requiring coating maintenance. The evaluation andstudy of the a Minnesota city’s 400,000-gallon steel water storage tank, completedby an engineering firm in 2002, revealed a need for renovation and a uniqueopportunity to conduct a test project with a new, NSF 61-approved, zinc-richcoating.

The Proposal

Working with three partners–coatings manufacturerSherwin-Williams; the City ofAnoka, MN; and coating contractor Classic Protective Coatings–engineering firmSEH, which had evaluated the tank, offered to conduct a side-byside test of twointerior paint systems with a single application of a moisture-cured urethane(MCU) organic zinc-rich coating. The coating had been recently approved by NSFInternational under standard ANSI/NSF 61 for use in potable water tanks. Liketraditional NSF 61-approved epoxy coatings for water tank interiors, the MCU or-ganic zinc-rich that would be tested is approved for application without a topcoat.

The goal was to differentiate between the coating system preferences of theowner (by applying coatings frequently used) and the coating system perform-ance (by comparing the frequently used systems with the single application ofzinc-rich coating). According to the coating manufacturer, this test project rep-resented the first time a zinc-rich coating on its own has been used in an actualin-service water tower. For the purpose of this study, performance was defined asthe lack of blistering and peeling. Further, performance was to mean less than10% corrosion—Rust Grade 4G—in accordance with SSPC-Vis 2, Standard Methodof Evaluating Degree of Rusting on Painted Steel Surfaces.

Performance or Preference:A Look at Selected Systemsfor Water Tank Interiors

Water TankInteriors

W

1

By Dan Zienty and Lee Dornbusch, Short ElliottHendrickson Inc., andTony Ippoliti, The Sherwin-Williams Company

Editor’s note: This article was published in JPCL in May 2007.The field research project describedhere received an honorable mentionaward for Engineering Excellence atthe Minnesota Section of the American Council of EngineeringCompanies.

“The Anoka watertank evaluationrevealed extensiverust bleed and corrosion alongthe edge of the structural support angles, the roof radial plate lapjoints, and similarareas notorious forpremature coatingfailures.”

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Background

Universal corrosion theory confirms that for rust to form on asteel surface, an anode, cathode, electrolyte, and metallic path-way must be present. If any of these elements are missing, cor-rosion 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 asanodes. Their proximity to one another provides the metallicpathway needed for the transfer of electrons. Rain, snow, con-densation, or potable water in a tank provides the electrolyticcomponent.

Corrosion is an electrochemical phenomenon. One methodto prevent corrosion is to prohibit the formation of rust by con-necting a more noble or “passive” metal (steel) to a less noble“active” metal. Less noble metals (zinc, in this example) act assacrificial anodic materials because providing the electrons thatprotect the steel surface eventually exhausts them. The anodeprovides the electrons that passivate the protected steel sur-faces, making it a cathode. In the case of a water storage tank,cathodic protection may be provided by an impressed currentsystem (see AWWA D104). Conceivably, lining the steel surfaceswith zinc-aluminum metalizing—a slow, very expensive, butlong-lasting alternative—could also provide passivation. One ofthe authors is aware of one municipality that has experiencedvery good corrosion protection using such a method.

The Anoka water tank evaluation revealed extensive rustbleed and corrosion along the edge of the structural roof sup-port angles; around the compression ring; between intermittentwelds, the upper shell stiffener ring, and roof; and at roof radialplate lap joints. These locations are notorious for prematurecoating failures because it is difficult to apply coating systemsin these nooks, crevices, and edges.

Condensation forms in these areas (hence, they are called “vapor areas”) andcauses premature coating failure, leading to rusting, flaking, or coating delami-nation. Such corrosion can lead to serious structural problems and costly repairsif left unchecked. Depending on the design of the tank, seal welding of roof-sup-porting members in the vapor areas may offer a permanent yet costly solution.However, in other tanks, seal welding cannot be done because it would preventthe movement or expansion that has been designed into such areas.

The evaluation allowed the following question to be raised: could an organiczinc 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 haveperformance similar to other barrier-type immersion-grade epoxy coating sys-tems? Barrier coatings protect against corrosion by preventing an atmosphericor 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 leador zinc-chromate had been used as primers under topcoat systems on the interiors

2

Completed test area: (left) epoxy/epoxy; (upper right) zinc-rich/epoxy/epoxy; (lower right) MCU zinc-richPhotos courtesy of the authors

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of water towers to protect steel from the effectsof corrosion; however, such pigments, whichwere based on heavy metals, were later deemeddetrimental to public health because of the heavymetal content. Rust-inhibitive coatings limit cor-rosion by having their corrosion-preventing pig-ments solubilize slightly under wet conditions.The solubilized pigments then act to passivatethe surface at the steel/coating interface. Manu-facturers of coatings intended for potable watercontact have their coatings tested to determinewhether solvents or other toxins leach from thecoatings. No coatings with such leachates are ap-proved for use in today’s drinking water tanks.Further, coating system approval for each proj-ect in Minnesota is also required by the Min-nesota Department of Health.

The engineering firm learned in 2002 that anew MCU organic zinc-rich immersion-gradecoating received NSF approval. The manufacturerformulated the coating so that it would receiveNSF 61-approval with or without a topcoat.

There are practical reasons for the manufac-turer’s approach to formulation. One reason is that, if the interior topcoat weredamaged in such a way to expose the NSF 61-approved zinc-rich coating, nothreat to the public would be derived from drinking water that was exposed to theMCU zinc-rich system. In the past, during the transition to NSF 61-approved coat-ings, water tank interiors were occasionally Brush-Off Blast Cleaned (SSPC-SP 7)prior to the application of “approved” coatings or coating systems. When thesecoatings were damaged—or worse, if they blistered—the existing, non-NSF-approved coatings would be exposed to the stored drinking water, creating apotential 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 ap-plication of the newly NSF-approved coating on the City’s 400,000-gallon tank.During development, the manufacturer conducted controlled test studies on theproduct, but had no “in-service” examples that would confirm its protective char-acteristics in water towers without a protective topcoat. To produce “in-service”evidence of its product’s capabilities, and understanding the risks to the City ofAnoka, the manufacturer agreed to assume full responsibility for paint, contrac-tor repairs, and inspection costs for coating failures (if any) in the test areas. Theinspection for failures would take place at the end of the two-year warranty givento the owner. The engineering firm also received approval from the MinnesotaDepartment of Health for this first-of-its-kind undertaking. Given this win-winscenario, the City approved the plan, and the engineering firm wrote the MCU or-

3

**Note: remaining interior areas of tank, not part of the test study region, protected with this coating system.

Table 1: Systems Tested

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ganic zinc-rich system and the guarantee into plans and specs that were sent tocontractors.

The case study consisted of applying the three coating systems shown in Table1 and Fig. 1 and comparing their performance. All three systems came from themanufacturer of the singlecoat product in the test.

The City took the tank out of service in June 2003. The specifications incorpo-rated a scope of work that included erecting a full-containment structure perSSPC-Guide 6, Class 2A, and completely removing interior and exterior coatings.Though the project schedule allowed seven weeks to complete the work, the con-tractor finished in four weeks and at $7,000 under budget, allowing the tank tobe returned to service earlier than anticipated.

Performance Evaluation

The engineering firm conducted a follow-up warranty inspection in June of 2005—two years after testing the three coatingsystems—including the inspection of thesingle-coat MCU zincrich. AWWA D102-03Standard, in Section 5.2.1.General, states:“When specified, the inside … surfaces ofthe tank shall be inspected within oneyear after coating work has been com-pleted, to determine whether any repairwork is necessary,” so this two-year war-ranted test period provided more thansufficient time for any problems to sur-face. At the engineering firm’s invitation,representatives of the coating manufac-turer participated in the inspection. Theinspection revealed no significant failuresof the single coat MCU organic zinc-richsystem when compared with the twomore traditional systems (Figs. 2 and 3).The only notable failures occurred over amanway cover, amounting to less than1⁄10 of 1% of the total test area. The fail-ure was traced to an application error, notto the product itself (Fig. 4).

Benefits

The initial success of the MCU zinc-richcoating, applied at 3 to 4 mils DFT, wasmeasured by the performance criteria es-tablished for this test project case study(no blistering or peeling, less than 10%corrosion per SSPC-Vis 4). This success in-dicated a method by which this watercommunity could save thousands of dol-

4

Fig. 2: Condition of support angle at warranty inspection for MCU Zinc-rich

Fig. 3: Condition of MCU zinc-rich on roof plates at warranty inspection

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5

lars on labor, material, time, and re-pairs needed due to corrosion of itsstorage tanks. The submerged areaof the tank totaled approximately9,000 square feet, a third of whichrepresented thevapor area that wasused for the case study. A manufac-turer’s recommendations for con-ventional coatings, in vapor zones,for example, may require a coatingthickness between 8 and 12 mils.The recommended applicationthickness for the MCU organic zinc-rich tested is much less, however,and there is no visible evidence ofunsuccessful coating performanceat this thickness. At an estimatedcost average of $6.25 per squarefoot using traditional systems,recognized savings in the test area

for labor and materials were estimated at $1.75 per square foot–significantsavings, especially if the single-coat system performs as long as or longerthan conventional systems.

Since the AWWA and many water professionals recommend periodic inspectionof water tanks every three to five years, the engineering firm has another inspection tentatively planned for 2009, at which time additional corrosionperformance results will be measured.

The performance data discovered in this two-year test project will be used toevaluate the longevity of the MCU zinc-rich coating as an alternative to conven-tional multi-coat coating systems for vapor zone renovation.

Future Value

Adopting a new coating technology or employing an existing coating in a newenvironment may require owners or engineers to adjust their thinking, but notnecessarily to accept greater risks. The engineering firm successfully imple-mented this test project case study without any risk to the client or to the safetyof their drinking water supply by providing the coating manufacturer the op-portunity to assume responsibility for a product in which it had great confidenceyet 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 testswere 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 nothave to go in front of our City Council and ask for another $100,000 to redo thejob, and the agreement [the engineering firm] negotiated with the paint manu-facturer to cover all labor and materials gave us the security and protection weneeded to proceed.”

Fig. 4: At the warranty inspection, the only notable failures were over a manway cover and were traced to an application error.

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“Really, our only concern was meeting the project timetable, as we had to havethe tank back on line by August when water demand is greatest. Though we set aseven-week schedule, the project was done three weeks early, and the tank wasback on line the first part of July. The project just went very smoothly, and showsthe potential that exists for municipalities to substantially save on labor and ma-terials involved in water tank painting and/or rehabilitation.”

The single-coat product SEH tested was Sherwin-Williams’ Corothane I Galva-pac, 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

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or water storage tank applications, alkyds, the much-trusted coatings of the past, weresummarily replaced by superior performing poly- urethane coatings in the late 1970s andearly 1980s. Polyurethanes were then, in the early 1990s, supplanted by polyurethaneswith clear coats and polyurethanes with UV protectors—coatings that promised resistanceto fading and a twenty-year service life. These later polyurethanes are now being chal-

lenged by fluorourethane and polysiloxane coatings—coatings that, although developed in the 1980s,are only recently being used for water storage tank applications. Fluorourethanes and polysiloxanesare 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.

Coating Systems for Water

Storage Tank Exteriors

Fluorourethane and siloxane coatings are rapidly gaining popularity with tank owners. The adver-tised thirty-year service life of these coatings is a big plus as regulations placed on coating removaland application procedures become stricter and the costs of materials and labor rise. The product

cost, however, makes most tank owners think twice and re-eval-uate 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, andthey are less expensive than the fluorourethane coatings. Silox-anes have a wider recommended application thickness rangeand are relatively easy to apply, with pot life exceeding the flu-orourethane coatings.

Life Expectancy What defines the end of an exterior coating’s service life? Whenthe first rust spot appears? When a certain percentage of primeris showing? When a certain percentage of rust is visible? Orwhen the finish coat is not aesthetically pleasing? For this arti-cle, the definition of the service life of a coating is the amount oftime before repainting becomes necessary due to coating failureand corrosion. Future touch-up may be required on isolatedcoating failures. If aesthetics are a concern, the owner may haveto topcoat the repainted tank before the end of the expectedservice life. However, future topcoating would be less expensivethan complete cleaning and recoating and could postpone theneed for complete cleaning and repainting for many years.

SpecificationDevelopment

A Comparison of Ultra-Long-LifeCoating Systems for WaterStorage Tanks

F

7

By Michael L. Doolittle, Tank Industry Consultants

Editor’s note: This article was publishedin JPCL in May 2009.

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

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Color Availability Most exterior tank coatings are available in practically all colors. Many times, color and aesthetic con-cerns drive the selection of the coating.

Ease of Application Generally, single-component materials dry on surfaces via the evaporation of the solvent, while mul-tiple-component materials generally cure by a chemical reaction of the materials. Some coating typesare more sensitive to atmospheric conditions than others, and this should be taken into account dur-ing 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 toperform as intended. For example, to perform properly, all components of amoisture-cured urethane must be mixed using the correct component ratiosand 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 somewhatmore difficult to use—it requires the applicator to reapply the coating to theroller more frequently because the shorter nap does not hold as much paintas the longer nap. Care needs to be taken to apply and roll the material toachieve the required dry film thickness.

Because of its sensitivity to coating thickness, a polyurethane clear coatis much more difficult to apply evenly and consistently. It is critical that thematerial be applied at the specified thickness—normally about 1 mil. Apolyurethane application can look great when it is completed, but once a yearor two has passed, any areas where the clear coat is too thick can yellow, andundercoats 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: van-dals throwing rocks or shooting at tanks, or, possibly, ice and snow build-upin cold weather. When vandals throw rocks and chip the coating, spot rust-ing may result. Our company’s experience shows that all of the finish coatingsare going to react similarly. If a tank has been damaged previously by van-dalism, consider using a zinc prime coat in which the zinc may help reduce therusting caused by a breach in the finish coat. The best strategy to reduce abra-sion from ice and snow is to make sure the material is applied with a smoothfinish so the ice and snow will slide off, with no lifted edges where moisturecan get in and lift the coating.

Resistance to Graffiti If the solvent in an anti-graffiti paint softens the underlying coating, graffiti will bond readily to theunderlying coating and will be difficult to remove. Ultra-high-performance coatings may reduce thedamage from graffiti because they provide a smoother finish, have lower surface energy, and aremore solvent resistant, thus giving the graffiti less “bite” into the surface. With high-performancepolyurethanes and ultra-high-performance fluorourethanes and polysiloxanes, graffiti can be re-moved, but it takes a lot of elbow grease using the appropriate thinner. Removing graffiti can re-move part of the finish coat, and often residual graffiti is visible. The only way to “remove” graffitifrom acrylics and alkyds is to apply coating over the graffiti, but matching the color of the originalcoating is often difficult.

8

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.

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Resistance to Fading (Color and Gloss Retention) Although alkyds and acrylics can be obtained in many colors, the poor color retention and gloss re-tention of these coatings should limit the color selection to light blues, light greens, light tans, andwhite. 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 be-cause, 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 fluo-rourethane three to five years ago do not appear to have faded nearly as much as we would have ex-pected had they been painted with a standard polyurethane. Longer in-service results for water tankapplications 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 UVradiation and as the coating pigments and binders break down. Chalking is usually an aesthetic con-sideration, except in extreme situations in which the thickness of the coating decreases and reducesthe 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 noteasy to topcoat for the same reasons. Although water tank applications of fluorourethanes and silox-anes have a short history, given their short recoat windows, abrading is normally required before top-coating or touch-up; polyurethanes with clear coats also require abrading prior to topcoating ortouch-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, chalk-ing normally causes the surface to become abraded. To provide good adhesion for the topcoating, itis 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 “dryfallout” characteristics. Because most water tank abrasive blasting projects are done inside contain-ment due to lead paint or nuisance dust restrictions, dry fall coatings are not as critical as they oncewere—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 sprayapplication. Application by brush and roller will reduce the amount of overspray because the coat-ing droplets will be larger and not travel as far. Polyurethane, fluorourethane, and polysiloxane coatings do not have good dry fall characteris-

tics. In addition, some of the dry fall acrylics cannot be applied by brush and roller and achieve goodresults.

Corrosion Resistance Corrosion resistance can be documented by many testing procedures that compare different coat-ing types under similar conditions. Because lead-based primers are no longer available, many coat-ings, such as alkyds, silicone alkyds, and acrylics, will not have the same corrosion resistance aspreviously manufactured coatings of the same generic type that contain lead or chromates.

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Coating Systems for Water

Storage Tank Interiors

Two- or three-coat tank interior epoxy coating systems have been a standard in the industry for thepast 25 years. Recent additions to the coatings specifer’s arsenal are zinc-primed epoxy andpolyurethane interior coating systems. Metalized coatings, also available for 25 years or so, are alsogaining 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 percent-age of rust is visible? The service life of an interior coating is defined in this article as the typicalexpected number of years before repainting becomes necessary due to excessive coating failure andcorrosion. The owner can extend the service life of the interior coating by installing and properlymaintaining and operating a cathodic protection system to help protect the interior submergedsteel surfaces that have experienced coating failure. Cathodic protection is not commonly usedwith zinc/aluminum spray-applied coatings.Epoxy or zinc-epoxy interior coatings are expected to last 15–25 years. Polyurethanes and met-

alized coatings have a significantly longer service life.

NSF 61 Certified ProductsThe National Sanitation Foundation (NSF) has established testing criteria for coatings in contact withpotable water. These criteria include protocol for bacteria growth, VOC contamination, and limits onother impurities in the cured coating system. Most states have adopted the NSF/ANSI 61 listing pro-cedure for tank interior coating systems; the participation status of all 50 U.S. states is provided inthe 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 ma-terial pot life. The higher performance interior coatings, such as polyurethanes and polyureas, are

one-application, multi-pass systems. These materials have a very shortrecoat window, and, once applied and set, require significant additionalsurface preparation for topcoating and touch-up. They are more difficultthan the standard epoxy systems to apply because they require specialplural-component spray guns, heaters, and other equipment, as well as adeep anchor pattern. Specialized training and certification is also requiredfor the applicator, and training is recommended for the equipment oper-ator. For the coating to perform well, the operator must make sure thecoating 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 higherdegree 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. TheSSPC-CS 23.00/AWS C2.23/NACE No. 12 joint standard is an excellentguide to use for specifying and evaluating metalizing systems.

Resistance to AbrasionApplied correctly, polyurethane coatings for tank interiors are very resistant to ice damage, whichis the only abrasion to which they are really subjected. Metalized coatings also have excellentresistance to corrosion and abrasion.

10

Equipment used in the application of metalized coating

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Ease of Topcoating It is not normally cost effective to topcoat standard epoxy interior tank coatings. However, whenultra-high-performance coatings are applied correctly, they may be very difficult to remove, and top-coating may therefore be an option. With the long expected service life of ultra-high-performancesystems, the need to topcoat has not come up yet. Based on experience so far, it is expected that spotrepair will extend the life of these coatings in water tank service. However, the surface will need tobe well abraded before any spot touch-up.

Corrosion ResistanceMetalizing and a zinc primer under an epoxy or polyurethane topcoat are the only tank interior coat-ing systems that offer corrosion resistance. Epoxy and polyurethane coatings offer a barrier, andpolyurethanes 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 spotto develop.) A metalized system has excellent resistance to corrosion.

Specialized Test EquipmentHigh voltage holiday testing is required for polyurethane tank interior coating systems that are ap-plied at more than 20 mils of dry film thickness. This test is more involved and more difficult touse than the standard low-voltage test.

Cost of MaterialsMetalizing is very expensive but has one of the longest life expectancies of any of the coatings dis-cussed. A sealer or finish coat is often recommended.

Conclusion

It is important to take into consideration many criteria when designing a coating system for eachtank 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 bedone 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 servicesmanager, he continues to be one of the primary liaisons between owners and contractors. He conducts failure analyses, is involved in dispute resolution, attends pre-constructionmeetings 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.

11

JPCL

Page 16: Selecting and Sourcing Coating Systems for Water  · PDF fileSelecting and Sourcing Coating Systems for Water Tanks A JPCL eBook

3M Corrosion Protection ProductsScotchkoteFusion-Bonded Epoxy (1-2 Coats)

ABRI IndustriesIronBond111Other

Avilion Inc.WasserMCU Zinc Rich/MCU/MCU

Blue Water Marine and Protective CoatingsMarine UrethaneEpoxy/Polyester/Polyester

Bowers IndustrialGulf CoastEpoxy (1-2 Coats)/Urethane

Bridgeport ChemicalGA 27PEpoxy 100% Solids (1 or 2 Coats)

(800) 722 - 6721www.3m.com/corrosion

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�����+"1/0.'#/IronBond 111Other

2')',+��+!�PPGEpoxy/Epoxy/Siloxane

�)1#���0#.���.'+#��+"��.,0#!0'2#��,�0'+%/Marine AC70/Marine UrethaneEpoxy/Polyester/Polyester

�,3#./��+"1/0.'�)Gulf Coast PaintEpoxy (1-2 Coats)/Urethane

��. ,)'+#��,*-�+5CarboxaneOrganic Zinc/Siloxane

�#0!,Perlastic SGCoal Tar/Asphalt

�&#*!,��+0#.+�0',+�)��0"�Epo-chem RL 500PFEpoxy/Epoxy/Epoxy

�,.!&#*��,.-,.�0',+Corchem 97/260/274Organic Zinc/Epoxy/Urethane

�,.,0#!&��'%&��#.$,.*�+!#��,�0'+%/CortechOrganic Zinc/Epoxy/Urethane

�,0#����+"1/0.'#/��+!�Durabak 18/Durabak 18 SmoothUrethane/Urethane

#+/,��,.0&�*#.'!�DensoTape Wraps

#2,#�������+0#.+�0',+�)���'+0�����Devoe High Performance CoatingsEpoxy (1-2 Coats)/Urethane

'�*,+"��,%#)���'+0��,*-�+5Finium DTM-ATOther

1.,*�.���+!�HPL-1110Epoxy 100% Solids (1 or 2 Coats)

�+"1.����+1$�!01.'+%��,���0"�EP521/EX-2CEpoxy (1-2 Coats)/Urethane

�+#!,+��,.-,.�0',+ChemcladEpoxy/Epoxy 100% Solids

�+2'.,+*#+0�)��.,0#!0'2#��,�0'+%/��+!�E-4000 One CoatZinc-Rich, Organic

�-,45��#!&��+0#.+�0',+�)MPC PlasticoOrganic Zinc/Epoxy/Urethane

�.%,+.*,.NovocoatEpoxy 100% Solids (1 or 2 Coats)

�)#4!.#0#��#!&+,),%'#/��0"�CemprotecEpoxy (1-2 Coats)/Acrylic (1-2 Coats)

�,4��+"1/0.'#/��+!�Fox FX-501M Elastomeric CoatingOther

�����,�0'+%/��+!�Rustop/SP-X Silicone Poly PlusEpoxy (1-2 Coats)/Urethane

��!,��#/0#.+�����GacoFlex S20Other

��.,+��.,"1!0/���+!�Mortarthane/AccelaresinPolyurea Hybrid (1, 2, or 3 Coats)

�#*'0#��.,"1!0/��+!�Fibre-PrimeOther

�), �)��!,�#!&+,),%'#/Endura-FlexUrethane Elastomeric (1 Coat)

�1)$��,�/0���'+0��$%����+!�GCPEpoxy (1-2 Coats)/Urethane

�#*-#)�������+!�17360/17630-3/5595UEpoxy (1-2 Coats)/Urethane

�#.#/'0#��.,0#!0'2#��,�0'+%/�����CSE-6200/UC-5500Epoxy (1-2 Coats)/Urethane

�'%&)�+"��+0#.+�0',+�)���+!�475R Dry-Fall/68R Dry-FallEpoxy (1-2 Coats)/Urethane

�����,*-,/'0#��#!&+,),%'#/CarbonSealEpoxy/Epoxy Novolac/Epoxy Novolac

�+"1.,+��,�0'+%/���+!�Perma-GlossInorganic Zinc/Epoxy/Fluorourethane

�+"1/0.'�)���+,0#!&��+!�Nansulate PTThermal Spray

�+0#%1*#+0��#!&+,),%'#/���+!�FluoroGripSheet Lining, Thermoplastic

�+0#.+�0',+�)���'+0����InternationalOrganic Zinc/Epoxy/Urethane

����*#.'!�+���$#05��#!&+,),%5AS-250Epoxy/Epoxy/Epoxy

�����,)5�-#!��101.���,�0'+%/Futura-ThaneEpoxy (1-2 Coats)/Urethane

������.0��,�0'+%/���+!�HP-105Urethane/Urethane

�����,..,/',+��,+0.,)��,����0"�Techni-Plus UR-5Urethane/Urethane

�#*-#.��5/0#*�*#.'!����+!�Kemperol 2K-PURUrethane/Urethane

�#+!#��,..,/',+��#.2'!#/����PetroGardTape Wraps

�,)' .'"��,�0'+%/���+!�Polibrid 705Urethane Elastomeric (1 Coat)

�,)5!,�0��.,"1!0/Polyeuro 7502Polyurea Pure (1, 2, or 3 Coats)

�,)5�-#!�������&',(,)PolySpec TuffRezEpoxy/Epoxy 100% Solids

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Coating System Guide for Water Works

Exterior ExposureWeathering and UVSteel

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12

Coating Systemsfor Water Works

Page 17: Selecting and Sourcing Coating Systems for Water  · PDF fileSelecting and Sourcing Coating Systems for Water Tanks A JPCL eBook

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�423��4,,&3���� Rust Bullet StandardOther

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�"4&1&*2&.���.$�SauereisenUrethane/Urethane

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�0&$*",38��1/%4$32���.$�������Polyshield HT-100F, AMP 100, CAP 100Polyurea Pure (1, 2, or 3 Coats)

�3*1,*.(��,/8%��1/40��,$�IntegritankMethyl Methacrylate/Methyl Methacrylate

�&1-"1423��&$)./,/(*&2Termarust TR2000 HR CSA SeriesCalcium Sulphonate

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�.&-&$� /-0".8���.$�Hydro-Zinc/UVX/HydroFlonOrganic Zinc/Urethane/Urethane

�/0��&$1&3� /"3*.(2Top SecretAlkyd/Alkyd/Silicone Alkyd

�23� &.3418� /"3*.(2���.$�FPUWC1Inorganic Zinc/Epoxy/Fluoropolymer

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�*241/.��&$)./,/(*&2��.$�PolyArmor, PolyProPolyurea Pure (1, 2, or 3 Coats)

�/,"3*,&��1&&���.$�Volatile Free, Inc.Polyurea Pure (1, 2, or 3 Coats)

�"22&1� /10/1"3*/.WasserMCU Zinc Rich/MCU/MCU

�"32/.� /"3*.(2���.$�Aqua-ShieldAlkyd/Acrylic/Acrylic

�/,5&1*.&� /"3*.(2� /10/1"3*/.LiquaTileEpoxy 100% Solids (1 or 2 Coats)

� ",*#41� /.2314$3*/.��823&-2��.$�UraLock UVOrganic Zinc/Epoxy/Urethane

!� ��/1,%6*%&ZRC-221 Cold Galvanizing CompoundZinc-Rich, Organic

������.%4231*&2Concrete Bond WROther

�$18,* /.��,//1*.(��/,43*/.2AcryliCon - DecorOther

�%5".$&%� )&-*$",��&$)./,/(*&2���.$�Sil-ActSiloxane/Siloxane

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�5*,*/.��.$�PPGEpoxy/Epoxy/Siloxane

�/6&12��.%4231*",DuromarEpoxy 100% Solids (1 or 2 Coats)

&3$/Perlastic SGCoal Tar/Asphalt

)&-$/��.3&1."3*/.",��3%�Epo-chem RL 500PFEpoxy/Epoxy/Epoxy

/.$1&3&��/,43*/.2��*5��/'��)*./��*.*.(2� /10�Epoxy 200Epoxy/Epoxy 100% Solids

/002��.%4231*&2���.$�Armorgard 700UVEpoxy 100% Solids (1 or 2 Coats)

/1$)&-� /10/1"3*/.Corchem 260/274Epoxy (1-2 Coats)/Urethane

/1/3&$)��*()��&1'/1-".$&� /"3*.(2CorotechEpoxy (1-2 Coats)/Urethane

/11/��)*&,%��.3&1."3*/.",���.$�Corro Aqua-ShieldEpoxy/Epoxy/Epoxy

/3&����.%4231*&2��.$�Durabak 18/Durabak 18 SmoothUrethane/Urethane

1/22'*&,%��1/%4$32� /10�Dex-O-TexEpoxy (1-2 Coats)/Urethane

1/6.��/,8-&12���� CrownPro 6 No VOCPolyurea Pure (1, 2, or 3 Coats)

�&.2/��/13)��-&1*$"DensoTape Wraps

�&5/&��� ���.3&1."3*/.",��"*.3��� �Devoe High Performance CoatingsEpoxy (1-2 Coats)/Urethane

Exterior ExposureWeathering and UVConcrete

�*"-/.%��/(&,��"*.3� /-0".8Vers-Acryl 200/Vers-Acryl 222Other

�41/-"1���.$�HPL-1110Epoxy 100% Solids (1 or 2 Coats)

�.%41"��".4'"$341*.(� /���3%�HiBuild/EX-2CEpoxy (1-2 Coats)/Urethane

�.&$/.� /10/1"3*/.ChemcladEpoxy/Epoxy 100% Solids

�0/78��&$)��.3&1."3*/.",MPC PlasticoEpoxy (1-2 Coats)/Urethane

�1(/.�1-/1NovocoatEpoxy/Epoxy 100% Solids

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�"$/��&23&1.���� GacoFlex S20Other

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�&-*3&��1/%4$32��.$�Tuff-Flex CAOther

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�4,'� /"23��"*.3��'(����.$�GCPEpoxy (1-2 Coats)/Urethane

�&-0&,��������.$�553US/17630-3/5595UEpoxy (1-2 Coats)/Urethane

�&1&2*3&��1/3&$3*5&� /"3*.(2���� CSE-6200/UC-5500Epoxy (1-2 Coats)/Urethane

��� /-0/2*3&��&$)./,/(*&2CarbonSealEpoxy/Epoxy Novolac/Epoxy Novolac

�.%41/.� /"3*.(2���.$�AC403 Elastomeric CoatingOther

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�.3&(4-&.3��&$)./,/(*&2���.$�FluoroGripSheet Lining, Thermoplastic

�����-&1*$".��"'&38��&$)./,/(8AS-250Epoxy/Epoxy/Epoxy

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13Water Works

Page 18: Selecting and Sourcing Coating Systems for Water  · PDF fileSelecting and Sourcing Coating Systems for Water Tanks A JPCL eBook

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�����02203+0/��0/420-��0����4&�Techni-Plus UR-5Urethane/Urethane

�'.1'2��934'.��.'2+%#���/%�Kemperol 2K-PURUrethane/Urethane

�'9��'3+/��0.1#/9Plasti-ChemieMethyl Methacrylate/Methyl Methacrylate

�2940/��/4'2/#4+0/#-��/%�Krystol T1, Krystol T2Other

������/%�Marseal 4000Sheet Lining, Thermoplastic

�024*'2/��/&5342+'3��/%�Hydro-Seal 75Epoxy Novolac (1 or 2 Coats)

�08��2'4'��20&5%43��2051Nox-Carb Stain & SealerSiloxane/Siloxane

�#%+(+%��0-9.'23�����+6+3+0/�0(���!�Elasto-Deck 6500Polyurea Pure (1, 2, or 3 Coats)

�0-+$2+&��0#4+/)3���/%�Polibrid 705Urethane Elastomeric (1 Coat)

�0-9%0#4��20&5%43Polyeuro 7502Polyurea Pure (1, 2, or 3 Coats)

�0-9�1'%�������*+0,0-PolySpec TuffRezEpoxy/Epoxy 100% Solids

�02�����/%�Por-15Urethane/Urethane

�����0#4+/)3PPC CoatingsOther

�����204'%4+6'����#2+/'��0#4+/)3AmercoatEpoxy (1-2 Coats)/Urethane

�20('33+0/#-��20&5%43�0(��#/3#3���/%�Professional Water Sealant PWS-5 RegularOther

�2030%0���/%�Weather SealSiloxane/Siloxane

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�*+/0��+/+/)3��02102#4+0/SolarMaxUrethane/Urethane

�0&&#��#+/4��02102#4+0/RoPon HS/Polycoat HSEpoxy (1-2 Coats)/Urethane

�534��-'5.��02102#4+0/9100/9800 SystemEpoxy (1-2 Coats)/Urethane

�#5'2'+3'/���/%�SauereisenUrethane/Urethane

�*'27+/�!+--+#.3Macropoxy 646/Hi-Solids PolyurethaneEpoxy (1-2 Coats)/Urethane

�1'%+#-49��20&5%43���/%�������Polyprime-100, Polyshield HT-100F, AMP 100Polyurea Pure (1, 2, or 3 Coats)

�4+2-+/)��-09&��2051��-%�IntegritankMethyl Methacrylate/Methyl Methacrylate

�'2.#2534��'%*/0-0)+'3Termaflex TX4000 SeriesOther

�/'.'%��0.1#/9���/%�EpoxoBloc WB/Enviro-CreteEpoxy (1-2 Coats)/Acrylic (1-2 Coats)

�01��'%2'4��0#4+/)3Top SecretAlkyd/Alkyd/Silicone Alkyd

�34��'/4529��0#4+/)3���/%�FPUWC1Epoxy (1-2 Coats)/Fluoropolymer

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'23#�-'8��/%02102#4'&FSS 45 DCPolyurea Pure (1, 2, or 3 Coats)

'8%0/��*'.+%#-3PowercoatEpoxy (1-2 Coats)/Urethane

+3520/��'%*/0-0)+'3��/%�PolyArmor, PolyProPolyurea Pure (1, 2, or 3 Coats)

0-#4+-'��2''���/%�Volatile Free, Inc.Polyurea Pure (1, 2, or 3 Coats)

!#33'2��02102#4+0/WasserMCU/MCU/MCU

!#430/��0#4+/)3���/%�Aqua-ShieldMethyl Methacrylate/Methyl Methacrylate

!0-6'2+/'��0#4+/)3��02102#4+0/LiquaTileEpoxy 100% Solids (1 or 2 Coats)

"��#-+$52��0/3425%4+0/��934'.3��/%�AntiCarb SOther

��!���*'34'240/��0�������0.103+4'3ARC PWEpoxy 100% Solids (1 or 2 Coats)

� ����/&5342+'3Abri Universal Sealer - MarineOther

�6+-+0/��/%�PPGEpoxy Novolac (1 or 2 Coats)

07'23��/&5342+#-DuromarEpoxy 100% Solids (1 or 2 Coats)

�#2$0-+/'��0.1#/9CarboguardEpoxy/Epoxy/Epoxy

�����0/��'%*�0(��#-+(02/+#���/%�Hydro-PoxEpoxy/Epoxy 100% Solids

Immersion ExposurePotable Water ApprovedSteel

�*'.%0��/4'2/#4+0/#-��4&�Epo-chem RA 500MEpoxy Flake Filled/Epoxy Flake Filled

�����/&5342+'3CIMUrethane Elastomeric (1 Coat)

�'60'�������/4'2/#4+0/#-��#+/4�����Devoe High Performance CoatingsEpoxy/Epoxy/Epoxy

�520.#2���/%�HPL-1110 PWEpoxy 100% Solids (1 or 2 Coats)

�/'%0/��02102#4+0/ChemcladEpoxy/Epoxy Novolac/Epoxy Novolac

�/6+20-+/'���/4'2/#4+0/#-��#+/4�����EnvirolineEpoxy 100% Solids (1 or 2 Coats)

�1089��'%*��/4'2/#4+0/#-Uroflex 61Epoxy/Epoxy 100% Solids

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�/&520/��0#4+/)3���/%�Perma-Clean 100 Ceramic EpoxyEpoxy 100% Solids (1 or 2 Coats)

�/&5342+#-��0#4+/)3�0(��0-02#&0Multiple brandsPolyurea Hybrid (1, 2, or 3 Coats)

�/4')5.'/4��'%*/0-0)+'3���/%�FluoroGripSheet Lining, Thermoplastic

�/4'2/#4+0/#-��#+/4����EnvirolineEpoxy/Epoxy 100% Solids

��!��'6%0/Brushable CeramicEpoxy/Epoxy/Epoxy

��!��0-9�1'%��5452#��0#4+/)3Protec IIPolyurea Hybrid (1, 2, or 3 Coats)

�#4+0/#-��#+/4'/#/%'��20&5%43��49���4&�JaxxonEpoxy/Epoxy 100% Solids

�����1'%+#-49��20&5%43NSP-120 High Performance Epoxy CoatingEpoxy 100% Solids (1 or 2 Coats)

�0-+$2+&��0#4+/)3���/%�Polibrid 705Urethane Elastomeric (1 Coat)

�0-9%0#4��20&5%43Polyeuro 5502 NSFPolyurea Pure (1, 2, or 3 Coats)

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14

Page 19: Selecting and Sourcing Coating Systems for Water  · PDF fileSelecting and Sourcing Coating Systems for Water Tanks A JPCL eBook

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�����/,1$"1(3$���� /(+$� , 1(+&0AmercoatEpoxy 100% Solids (1 or 2 Coats)

�2 +12*��/,2-Precidium P-180D, Precidium 650PWPolyurea Pure (1, 2, or 3 Coats)

� 3$+��(+(+&��601$*0Raven Lining SystemsEpoxy 100% Solids (1 or 2 Coats)

�'(+,��(+(+&0� ,/-,/ 1(,+Rhino Extreme PWPolyurea Pure (1, 2, or 3 Coats)

�201��)$2*� ,/-,/ 1(,+W9200 SystemEpoxy/Epoxy/Epoxy

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�'$/4(+��())( *0Copoxy Primer/Mac 646 PWEpoxy/Epoxy/Epoxy

�-$"( )16��/,#2"10���+"�������Watersafe Primer, Watersafe 100-NSF PolyureaPolyurea Pure (1, 2, or 3 Coats)

�-$"1/ �'($)#��(+$/��601$*0SpectraGardeUrethane/Urethane

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�1(/)(+&��),6#��/,2-��)"�PermareOther

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�(02/,+��$"'+,),&($0��+"�PolyArmor, 1010PWPolyurea Pure (1, 2, or 3 Coats)

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�+3(/,)(+$���+1$/+ 1(,+ )�� (+1��� �EnvirolineEpoxy 100% Solids (1 or 2 Coats)

�-,56��$"'��+1$/+ 1(,+ )Epoxytec CPPEpoxy 100% Solids (1 or 2 Coats)

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�2")(#� '$*(" )� ,*- +6HeyDi K-11Other

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Click our Reader e-Card at paintsquare.com/ric

Water Works

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15Water WorksClick our Reader e-Card at paintsquare.com

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�.1%$.��&1�(&+01.1*,(5Endura-FlexUrethane Elastomeric (1 Coat)

�(0-(.��14214$6,10<�14415,10��0*,0((4,0*Acroline HDPESheet Lining, Thermoplastic

����1/215,6(��(&+01.1*,(5CarbonSealEpoxy/Epoxy Novolac/Epoxy Novolac

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Page 21: Selecting and Sourcing Coating Systems for Water  · PDF fileSelecting and Sourcing Coating Systems for Water Tanks A JPCL eBook

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Page 22: Selecting and Sourcing Coating Systems for Water  · PDF fileSelecting and Sourcing Coating Systems for Water Tanks A JPCL eBook

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Page 23: Selecting and Sourcing Coating Systems for Water  · PDF fileSelecting and Sourcing Coating Systems for Water Tanks A JPCL eBook

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Page 24: Selecting and Sourcing Coating Systems for Water  · PDF fileSelecting and Sourcing Coating Systems for Water Tanks A JPCL eBook

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