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Ecodur 201: XTO Secondary Containment Project by Aquablocx

The frac’ing business handles vast quantities of waste water, much of it exposed to contamination from chemicals and gases such as hydrogen sulphide and methane. The frac water itself often starts out as a cocktail of chemicals specially designed to do a highly specific task of helping release the trapped gases and oil in the shale rock after it has been fractured by hydraulic pressure.

Castagra Storage Tank Coating

Problem

Water storage handling and storage in this case study took the form of a below ground tank 92 feet by 32 feet and 8 feet in depth with a metal grille top. The walls were poured three months prior to the coating job as was a 4 foot wide 110 foot concrete trough that linked the dump station to the tank. Inspection showed the concrete tank walls had honeycombing and, in some cases, holes the size of a fist.

Surface prepping took the form pressure washing with warm water and remediating tank holes with a BASF mortar plug. The prevailing temperatures throughout the five-day job was in the teens Fahrenheit with the thermometer barely creeping over 32 degrees on occasion. The walls were dried using propane heaters with a plastic tarp put over the grille top of the tank to keep the heat in. The floors were vacuumed clean.

Prepping took a total of three days at the XTO Energy site and had also involved removing a lot of mud that had swept in from some adjacent high ground that had been excavated. In total 14 significant tank leaks were resolved before the final spray work with Ecodur 201S.

A secondary containment trench 105 feet long also required remedial work and a spray coating but it did not present the same difficulty level as the tank.

However, a concrete ramp presented almost as much difficulty as the tank itself as where it attached to the tank there was no water stop and flaws allowed a significant leakage of about a gallon an hour. After much repair effort, the leakage was reduced to an insignificant level.

XTO_Coating_Project

Solution
The poor state of the concrete overall, despite its relative newness, was largely due to it not having been vibrated sufficiently during pouring hence the honeycombing and also the walls had not been rubbed with repair mortar. The vast majority of the holes were small and the Ecodur spray coating fixed those readily with the larger holes, as previously mentioned, being plugged manually with special mortar.

Coating between Tanks

Application Results
The original poor state of the concrete and absence of a water seal at a critical point with the ramp, had provided unique problems to start with prior to the coating. The Ecodur performed as intended with about 185 gallons used in this concrete coating project.

With its particular protective qualities, the client had required a coating that would provide high protection performance with regard to H2S, methane and certain acids. Ecodur being VOC and solvent free and completely non-toxic, also provided these benefits for the applicators who had to work in very cold conditions. With no solvents used in the content of the Ecodur, its application or clean-up, there was simply no solvent disposal issue as is the case with many conventional epoxy coatings.

Ecodur’s exceptional cold weather performance meant that the applicators could carry out the work in the very cold conditions with confidence, again a particular feature of Ecodur when compared to conventional epoxy coatings.

Concrete Coating

Ecodur 201 Coating

Industrial CoatingProtective Coating

Solvent Free Coating