The Oasis Plant of Pompano Beach, Florida, treats wastewater from the Broward County North Regional Wastewater Facility. The OASIS plant filters water through a variety of different processes, including the EcoWash process, and it is home of the first EcoWash facility in the United States. Water at this plant is tested and monitored to meet a number of water quality parameters, including nitrogen, phosphorus, sodium hypochlorite, and chlorine levels. Due to exposure to these corrosive substances, rehabilitation and maintenance of the facility is a constant need.
A chlorine room within the facility was one such area that required rehabilitation. The area measured over 1,400 square feet (with the coverage approximately 36 inches up the wall), and it needed attention due to exposure to sodium hypochlorite. The concrete pads on which the tanks sat had rebar corroding, and there was cracking in the concrete all along the edges. Initially, removing of the compromised concrete and rebuilding the edges to specification was considered. Cesar Castillo of MCOR was contacted to assist with the application and oversight. MCOR manufactures and supplies industrial repair and coating polymers designed primarily for maintenance. Mr. Castillo suggested that the pads be cut down instead of removed to completely eliminate the compromised concrete, save money on materials, and establish a sound base on which to start sealing the edges from the floor thus minimizing water intrusion under the pads.
Mr. Castillo then recommended the use of MCOR 5101 | mCrete R Gel, a high-performance, multipurpose concrete repair epoxy paste, to rehabilitate and seal the area followed by the application of MCOR’s high chemical resistance product, MCOR 1298 | mCoat IM Plus, to further protect the area.
Surface preparation began with the removal of all loose concrete and rust on all exposed areas and left-over rebar. To etch areas so the coating could perform well as a liner, the entire area was washed down with a muriatic acid wash, including the wall sections along the entire perimeter, followed by a thorough rinse and fan dry.
MCOR 5101 | mCrete R Gel was then used to seal the concrete pads and their edges as well as the bottom perimeter of the room.MCOR 5101 is a 100% solid epoxy repair polymer for concrete and masonry applications. Filled with reinforcing fibers and various silicates, the polymer creates a permanent seal for shallow and deep repairs- to fill, patch, re-anchor, and restore. mCrete R Gel can bond to most surfaces and hang vertically, and it exhibits incredible bond strength.
While simultaneously broadcasting Clean Sand-6/20 Coarse (used to provide a safety grip system), the first coat of MCOR 1298 was applied specifically to the floor and walking areas but not on the pads, so the tank warranty would not be compromised.
MCOR 1298 | mCoat IM Plus is a two-component, ultra-high chemical resistant phenolic novolac epoxy. Novolac technology is best-in-class for high-chemical environments.
mCoat IM Plus has been designed to specifically protect, seal, and outperform in environments that are immersed or that experience flow or splash. It provides terrific seamless, monolithic lining to seal and provide barrier containment from the environment, and it has a smooth film, high gloss, impact resistance, blush resistance, chemical resistance, and UV tolerance. The second coat of the MCOR 1298 was applied within the recoat window of 4 – 72 hours.
Another added benefit of using MCOR is that it gives clients the ability to train maintenance teams on its advanced mechanical polymers at no additional cost, thus enabling cities to keep projects in-house.
This Oasis Plant project was completed on time and was kept in-house (except for cutting down the pads) due to the ease of application of MCOR products, which translated into significant cost savings for the City of Pompano Beach.
For more information on MCOR 5101 | mCrete R Gel, visit mcor.net/mcor-product/mcor-5101-mcrete-r-gel/.
For more information on MCOR 1298 | mCoat IM Plus, visit mcor.net/mcor-product/mcor-1298-mcoat-im-plus/.
To learn more about MCOR’s complete product line, visit mcor.net/products.
PROJECT: Chlorine Room Rehabilitation
OWNER: Oasis Plant of Pompano Beach, Florida
DATE: First Quarter 2016
PRODUCTS: MCOR 1298 | mCoat IM Plus and MCOR 5101 | mCrete R Gel