The Importance of an Engineering Condition Assessment (ECA) for Proper Implementation of Structural Rehabilitation Methods

Engineering Condition Assessment (ECA) is the first step in a series of actions aimed at restoring or improving a structure’s integrity and functionality. This process involves a detailed examination of the physical condition of a structure, using a combination of visual inspections, non-destructive testing, and material analysis. The data collected during an ECA provides invaluable insights into the extent of deterioration, the effectiveness of existing systems, and the need for structural enhancements. This assessment is essential for tailoring rehabilitation methods to the specific needs of a structure, ensuring that any interventions are both appropriate and effective.

Identifying and Addressing Structural Vulnerabilities

One of the primary objectives of an ECA is to identify structural vulnerabilities that could compromise the safety and stability of a building or infrastructure. By pinpointing areas of concern early on, engineers can devise strategies to address these issues before they escalate into major problems. This proactive approach not only saves time and resources but also minimizes the risk of structural failures that could have dire consequences.

Extending Infrastructure Lifespan through Targeted Rehabilitation

The insights gained from an ECA enable engineers to extend the lifespan of infrastructure through targeted rehabilitation efforts. By addressing the root causes of deterioration and implementing tailored solutions, structures can be preserved and strengthened for future generations. This not only ensures the continued usability of important infrastructure but also contributes to sustainability by reducing the need for new constructions.

Enhancing Safety and Compliance through Systematic Evaluation

Safety is a paramount concern in any construction or rehabilitation project. An ECA provides a systematic evaluation of a structure’s safety features, ensuring that they meet current standards and regulations. This process helps identify potential hazards, allowing for the implementation of measures to protect both users and the general public. Additionally, an ECA ensures compliance with building codes and industry standards, safeguarding against legal and financial repercussions.

Cost-Effective Planning and Resource Allocation

An Engineering Condition Assessment facilitates cost-effective planning and resource allocation by highlighting the most critical areas for intervention. This targeted approach ensures that funds and efforts are directed towards the most impactful rehabilitation measures, optimizing the use of available resources. By prioritizing interventions based on the severity of issues and their potential impact on structural integrity, stakeholders can achieve maximum benefits with minimal expenditure.

Tailoring Rehabilitation Methods to Specific Structural Needs

The detailed information provided by an ECA allows for the customization of rehabilitation methods to suit the specific needs of a structure. Whether it’s reinforcing weakened elements, addressing corrosion, or upgrading materials, each intervention is designed to address the unique challenges identified during the assessment. This personalized approach ensures that rehabilitation efforts are not only effective but also sustainable in the long term.

Conclusion

The importance of an Engineering Condition Assessment (ECA) for proper implementation of structural rehabilitation methods cannot be overstated. It is the foundation upon which safe, effective, and sustainable rehabilitation projects are built. By providing a detailed understanding of a structure’s condition, ECAs enable targeted interventions that enhance safety, extend lifespan, and ensure compliance. As the construction industry continues to evolve, the role of ECAs in facilitating informed decision-making and innovative rehabilitation strategies will only grow in significance.

FAQs

How does an Engineering Condition Assessment improve the safety of structures?

An ECA identifies potential hazards and structural vulnerabilities, allowing for the implementation of measures to enhance safety and ensure compliance with standards.

What are the benefits of targeting rehabilitation efforts based on ECA findings?

Targeted rehabilitation saves resources by focusing efforts on the most critical issues, extends infrastructure lifespan, and enhances safety and functionality.

Can an ECA prevent future structural problems?

Yes, by identifying and addressing the root causes of deterioration, an ECA can prevent future issues and reduce the likelihood of costly repairs.

How does an ECA contribute to sustainability in construction?

By extending the lifespan of existing structures and optimizing resource use, ECAs support sustainability by reducing the need for new constructions and minimizing waste.

What role does technology play in Engineering Condition Assessments?

Technology, including non-destructive testing and material analysis, plays a crucial role in accurately assessing a structure’s condition and identifying issues.

Why is compliance with building codes and standards important in structural rehabilitation?

Compliance ensures that structures are safe, functional, and legally sound, protecting stakeholders from potential legal and financial repercussions.

Table of Contents

1. Introduction to Certified Construction Project Management

2. Field Consulting Engineering: The Blueprint of Success

3. Meticulous Planning: The Foundation of Flawlessness

4. Strategic Implementation: Turning Plans into Reality

5. Rigorous Control and Monitoring: Keeping Projects on Track

6. Contract Closeout: Sealing the Deal with Precision

7. Thorough Inspections: The Final Layer of Assurance

8. Quality Assurance and Control: The Cornerstones of Excellence

9. Exceeding Expectations: The MADERO Company Promise

10. FAQ About MADERO Construction Project Management

Introduction to Certified Construction Project Management

MADERO Certified Construction Project Management service embodies a holistic approach to construction oversight. This service is not merely about managing timelines and budgets; it’s about ensuring that every phase of the project is executed with the highest degree of precision and excellence. The goal is to transform visions into tangible realities, adhering to the initial vision while ensuring compliance with all regulatory standards and expectations.

Field Consulting Engineering: The Blueprint of Success

The journey of excellence begins with field consulting engineering, where experienced professionals lay the groundwork for success. This initial phase involves a thorough assessment of the project’s requirements, potential challenges, and the formulation of a strategic roadmap. It’s about creating a blueprint that is both realistic and optimized for success, ensuring that the foundation of the project is as strong as the materials used to build it.

Meticulous Planning: The Foundation of Flawlessness

At the heart of MADERO service is meticulous planning. This stage is critical in preempting challenges and devising strategies to mitigate them. Detailed planning encompasses everything from resource allocation to scheduling and risk management. It’s about laying a path that is clear, efficient, and devoid of unnecessary hurdles, ensuring that the project progresses smoothly from one phase to the next.

Strategic Implementation: Turning Plans into Reality

With a solid plan in place, strategic implementation takes center stage. This phase is where the theoretical meets the practical, and plans are brought to life. MADERO Company excels in executing strategies with precision, employing a hands-on approach to ensure that every aspect of the project aligns with the predetermined blueprint. It’s about turning visions into tangible outcomes, with an unwavering focus on quality and detail.

Rigorous Control and Monitoring: Keeping Projects on Track

To ensure that projects remain on track, MADERO Company implements rigorous control and monitoring practices. This continuous oversight allows for the early detection of potential deviations from the plan, enabling timely interventions. It’s a proactive approach to project management that guarantees adherence to timelines, budgets, and quality standards.

Contract

 Closeout: Sealing the Deal with Precision

The culmination of a project doesn’t signify the end of MADERO involvement. Contract closeout is handled with the same level of precision as every other phase. This includes ensuring that all contractual obligations have been fulfilled, conducting final inspections, and confirming that the project meets all quality and compliance standards.

Thorough Inspections: The Final Layer of Assurance

Before a project is deemed complete, MADERO Company conducts thorough inspections. This final layer of assurance is pivotal in guaranteeing that every detail, no matter how minute, aligns with the highest standards of quality and safety. It’s the final checkpoint in a journey of excellence, ensuring that the project not only meets but exceeds expectations.

Quality Assurance and Control: The Cornerstones of Excellence

Quality assurance and control are the cornerstones of MADERO approach. These practices are embedded in every phase of the project management process, ensuring that excellence is not just a goal but a guarantee. It’s about delivering outcomes that stand the test of time, reflecting a commitment to quality that is unmatched.

Exceeding Expectations: The MADERO Company Promise

MADERO Certified Construction Project Management service is more than just a solution; it’s a promise to exceed expectations. With a team of experts dedicated to achieving excellence, clients are assured of a partner that brings unparalleled expertise, a commitment to quality, and a proactive approach to managing every aspect of their construction projects.

FAQ About MADERO Company’s Construction Project Management

Q: What makes MADERO Construction Project Management service unique?

A: The service’s uniqueness lies in its comprehensive approach, which covers every aspect of project management with an unwavering focus on excellence, precision, and quality assurance.

Q: Can MADERO Company handle projects of varying complexities?

A: Absolutely. MADERO is equipped to manage construction projects of any complexity, leveraging its expertise and methodologies to ensure success.

Q: How does MADERO ensure adherence to timelines and budgets?

A: Through meticulous planning, strategic implementation, and rigorous monitoring, MADERO ensures that projects stay on track, meeting all timeline and budgetary constraints.

Q: What role does quality assurance play in MADERO service?

A: Quality assurance is central to MADERO approach, ensuring that every project not only meets but exceeds the highest standards of quality and compliance.

Why Concrete Manholes with Epoxy Coating Are the Optimal Choice

The choice between concrete manholes with epoxy coating and other materials like polymer concrete or fiberglass is pivotal for infrastructure longevity and financial prudence. Epoxy-coated concrete manholes, with their impressive lifespan of more than 75 years, stand out for several compelling reasons.

Unmatched Durability and Structural Integrity

Epoxy-coated concrete manholes offer exceptional durability against physical and chemical wear. The epoxy coating acts as a protective barrier, safeguarding the concrete from corrosive substances and water infiltration, which are common in underground environments. This enhanced resilience translates to reduced maintenance costs and longer service life, making them a prudent investment for municipal and industrial projects.

Cost-Effectiveness Over the Long Haul

While the initial investment in epoxy-coated concrete manholes might be higher than fiberglass or polymer alternatives, the long-term savings are significant. Their extended lifespan and low maintenance requirements mitigate the need for frequent replacements or costly repairs, offering unparalleled cost-effectiveness over decades.

Environmental Sustainability

The sustainability factor of epoxy-coated concrete manholes is another vital aspect of their superiority. Concrete is a widely available and recyclable material, and when combined with epoxy—a substance known for its durability and chemical resistance—the result is an environmentally friendly solution that minimizes waste and resource consumption.

Enhanced Safety Features

Safety is a paramount concern in the design and selection of manholes. Epoxy-coated concrete manholes provide superior resistance to fire and hazardous chemicals, reducing the risk of accidents and ensuring the safety of maintenance personnel and the public.

Aesthetic and Functional Versatility

The aesthetic and functional versatility of epoxy-coated concrete manholes is noteworthy. The epoxy coating can be customized in various colors and finishes, accommodating aesthetic preferences and visibility requirements. Additionally, the adaptability of concrete allows for customized shapes and sizes, ensuring that each manhole meets the specific demands of its application.

The Comparative Analysis: Epoxy-Coated Concrete vs. Polymer and Fiberglass

Comparing epoxy-coated concrete manholes to polymer concrete and fiberglass alternatives highlights their superiority in several dimensions, including durability, cost-effectiveness, environmental impact, and safety. While polymer concrete and fiberglass may offer certain advantages, such as lighter weight or ease of installation, they fall short in terms of lifespan and long-term financial and environmental benefits.

The Role of Technological Advancements

Technological advancements in epoxy formulations and concrete manufacturing have further cemented the position of epoxy-coated concrete manholes as the preferred choice. Innovations in materials science have led to epoxy coatings that are more resilient and environmentally friendly, enhancing the overall value proposition of this solution.

Meeting the Challenges of Urbanization

As urbanization intensifies, the demand for reliable and sustainable infrastructure solutions becomes critical. Epoxy-coated concrete manholes address this need effectively, offering a solution that withstands the test of time and the challenges posed by increasing urban density and environmental concerns.

The Global Perspective: Adoption and Success Stories

Globally, the adoption of epoxy-coated concrete manholes is on the rise, with numerous success stories underscoring their effectiveness. From major cities to industrial complexes, these manholes have proven their worth, demonstrating significant savings in maintenance and replacement costs, along with positive environmental impacts.

FAQs

• What makes epoxy-coated concrete manholes more durable than fiberglass?

The epoxy coating provides superior protection against corrosion and water infiltration, significantly enhancing the durability of concrete manholes compared to fiberglass.

• How do epoxy-coated concrete manholes contribute to environmental sustainability?

Their long lifespan, low maintenance needs, and the recyclability of concrete make them an environmentally friendly choice, reducing waste and resource consumption.

• Can epoxy-coated concrete manholes be customized for specific projects?

Yes, their design can be tailored in terms of size, shape, and color, offering versatility to meet the unique requirements of various applications.

• What are the cost benefits of choosing epoxy-coated concrete manholes over polymer concrete ones?

The extended lifespan and reduced maintenance needs of epoxy-coated concrete manholes translate to significant long-term savings, outweighing the initial cost difference.

• Are epoxy-coated concrete manholes safe for use in high-traffic areas?

Yes, their robust construction and resistance to hazardous chemicals make them safe and reliable for use in both urban and industrial environments.

• How has technology improved the efficacy of epoxy coatings for concrete manholes?

Advancements in materials science have resulted in more durable and environmentally friendly epoxy formulations, enhancing the protective qualities of the coating.

Conclusion

Concrete manholes coated with epoxy stand as a testament to innovation, sustainability, and economic foresight in infrastructure development. Their adoption not only signifies a commitment to enduring quality but also reflects a conscious choice towards environmental responsibility and safety. As cities and industries evolve, the preference for epoxy-coated concrete manholes is poised to grow, underlining their role as the cornerstone of modern, resilient, and cost-effective underground infrastructure solutions.

In the realm of construction and engineering, the difference between a standard project and an exemplary one often lies in the details of craftsmanship, innovation, and the precision of execution. MADERO Licensed Specialty Contractor Service epitomizes this ethos, providing a comprehensive, end-to-end solution that caters to the nuanced demands of sophisticated construction projects. From the foundational phase of accurate estimating to the detailed work of surface preparation, and the finesse in the installation of coatings and Fiber Reinforced Polymer (FRP), MADERO team exemplifies professionalism at every turn. This article unfolds the layers of expertise and dedicated service that MADERO brings to the forefront, ensuring that each project not only meets but surpasses expectations with enduring results.

Table of Contents

1. Unveiling MADERO Specialty Services

2. Estimating: The Art of Precision

3. Surface Preparation: Setting the Stage for Excellence

4. Coating Installation: A Testament to Durability

5. The Role of Fiber Reinforced Polymer (FRP)

6. Quality Control: Ensuring Superior Finishes

7. Beyond the Surface: Structural and Leak Repairs

8. A Spectrum of Services: Engineering to Consulting

9. The Certifications That Set MADERO Apart

10. Adapting to Various Sectors

11. FAQ About MADERO Specialty Contractor Services

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Unveiling MADERO Specialty Services

MADERO Licensed Specialty Contractor Service stands as a beacon of excellence in the construction and engineering industry. The service encompasses a holistic approach to project management, integrating the finest practices in estimating, surface preparation, and the installation of advanced materials like coatings and FRP. MADERO´s expertise is not confined to mere construction; it extends into rigorous quality control testing, structural and leak repairs, and a broad spectrum of engineering, management, and consulting services across multiple sectors. This comprehensive service offering is underpinned by MADERO’s commitment to safety, professionalism, and the delivery of exceptional results.

Estimating: The Art of Precision

The initial phase of any project involves accurate estimating, a critical process where MADERO excels. The team’s proficiency in assessing the scope, materials, labor, and time requirements sets the foundation for a project’s success. By employing advanced software and methodologies, MADERO ensures that estimates are precise, realistic, and tailored to meet the unique needs of each project.

Surface Preparation: Setting the Stage for Excellence

Surface preparation is a pivotal step in the construction process, one that MADERO approaches with meticulous attention to detail. The preparation process involves thorough cleaning, smoothing, and priming surfaces to ensure optimal adherence of coatings and FRP. This careful preparation not only enhances the durability of the finishes but also contributes to the longevity and integrity of the project.

Coating Installation: A Testament to Durability

Coating installation is a specialty of MADERO , where the team’s vast knowledge and technical skills come to the forefront. MADERO’s expertise in selecting and applying the appropriate coatings for each project guarantees superior finishes that are resistant to wear, corrosion, and environmental impacts. This commitment to quality and durability is evident in every project Madero undertakes.

The Role of Fiber Reinforced Polymer (FRP)

Fiber Reinforced Polymer (FRP) represents a revolutionary material in the construction industry, known for its strength, lightweight properties, and versatility. MADERO mastery in the application of FRP enhances

the structural integrity and performance of projects. This innovative material offers an effective solution for reinforcing structures, providing resistance against environmental stressors and extending the lifespan of construction projects.

Quality Control: Ensuring Superior Finishes

Quality control stands at the core of MADERO service ethos. Through rigorous testing and inspections, MADERO ensures that every aspect of a project adheres to the highest standards of quality. This unwavering dedication to excellence guarantees that finishes are not only aesthetically pleasing but are also durable and reliable.

Beyond the Surface: Structural and Leak Repairs

MADERO services extend beyond surface treatments to encompass structural and leak repairs. These services provide robust and reliable solutions to any issues that may arise during or after the construction process. MADERO´s approach to repairs is characterized by thoroughness, ensuring that structures are not only fixed but are also fortified against future problems.

A Spectrum of Services: Engineering to Consulting

MADERO offers a wide range of services that span engineering, construction management, and consulting. This versatility allows Madero to adapt to the diverse needs of various sectors, solidifying its reputation as a trusted, comprehensive solutions provider. Whether it’s a critical infrastructure project or a fast-paced commercial development, Madero’s team is equipped to handle the challenges and complexities with expertise and professionalism.

The Certifications That Set MADERO Apart

MADERO commitment to excellence is further evidenced by its array of certifications in safety, project management, and specialized applications. These certifications reflect MADERO ‘s adherence to industry standards and best practices, ensuring that clients are partnering with a firm that is recognized for its competence and professionalism.

Adapting to Various Sectors

MADERO ability to adapt its services to various sectors is a testament to its versatility and expertise. From residential and commercial construction to industrial and infrastructure projects, MADERO ‘s team leverages its wide-ranging skills to deliver solutions that meet the specific needs and challenges of each sector. This adaptability ensures that MADERO remains at the forefront of the construction and engineering industry, ready to tackle projects of any scale and complexity.

FAQ About MADERO Specialty Contractor Services

Q: What makes MADERO services unique?

A: MADERO services stand out for their comprehensive approach, encompassing everything from precise estimating to quality control, and the use of advanced materials like FRP. MADERO ‘s commitment to safety, quality, and delivering exceptional results sets it apart in the industry.

Q: How does MADERO ensure project success?

A: Through meticulous planning, expert execution, and rigorous quality control measures, MADERO ensures that every project is completed to the highest standards, meeting and often exceeding client expectations.

Q: Can MADERO handle projects in different sectors?

A: Yes, MADERO is well-equipped to manage projects across multiple sectors, thanks to its broad spectrum of services and expertise in engineering, construction management, and consulting.

INITIAL CONDITIONS:

• The black control steel test plate, on the left side of figure 1, was coated with a typical anti-corrosion coating used by the shrimp farm owner at the pumping station equipment.
• The white steel test plate on the right hand side is coated with Warren Epoxy.
• The objective of the test was to check after 3 months of total immersion (about 2 ft in depth) at the shrimp farm seawater supply channels, the condition of the coatings after barnacles fouling attack.

FINAL CONDITIONS AFTER 3 MONTHS OF BARNACLES FOULING RESISTANCE TESTING:

• The control plate coating did not survive the barnacles fouling attack. it presented symptoms of an apparent coating breakdown by mechanism of osmotic blistering and disbondment (a.k.a. osmotic gradient action), and corrosion.
• As noted in figures 2 and 3 below, our steel plate coated with the Warren Epoxy easily survived the 3 months of barnacle fouling resistance testing.
• Once removed from the seawater (shrimp farm) supply channel, the white plate was hydrowashed with 3,000 psi water. The barnacles easily disbonded from the coating.
• The Warren Epoxy coated plate was found to be in very good structural condition. the steel plate had no signs of corrosion or coating failure.
• This test was considered a very successful because it shows the resilience and armor type protection provided by our outstanding the warren epoxy coating against a severe barnacles attack.
• The subject test results supports the long term life expectancy of the structural repair made in concrete pile foundation’s tidal zone region (Ref. Proj. #13). Furthermore, it is important to note that our Warren Epoxy alone can easily protect the pile foundations tidal zone areas from erosion and corrosion. It is assumed that structural capacity repair of the subject pile area is not required.

INITIAL CONDITIONS:

The Anheuser Busch Carterville facility is one of the largest of its kind and one of the most advanced in north America. It has its own wastewater pre-treatment plant that has been operating since 1993, handling brewery process wastewater as well as local municipal flows. Typical treatment capacity is 2.5 to 3 mgd (i.e. Millions of gallons per day). The plant never had a permit violation. This Anheuser Busch brewery is located in Cartersville, Georgia, USA.

The plant included digester facilities and equalization basins frequently exposed to the toxic, flammable, and highly corrosive H2S (hydrogen sulfide gas) in the operating range of 500 and 2000 ppm. Because of the severe amount of H2S in these processess areas, significant corrosion quickly started to destroy the structural integrity of the concrete and created leakage problems. The initial corrosion prevention product applied when the structure was built, failed shortly after installation. In 1998, and after approximately five years of extensive research and coatings evaluations, Anheuser Busch decided to apply Warren Epoxy.

Due to the outstanding corrosion and structural integrity protection provided by the Warren Epoxy coating at the subject facility, this product has since been applied to other Anheuser Busch Wastewater plants and facilities nationwide.

In 2013, the prestigious World Class Engineering Magazine “ENR News-Record” featured the cutting edge emergency and fast track rehabilitation of a badly corroded and structurally deteriorated 3 Million Gallons Portable Water Tank in Las Vegas, Nevada, USA. The Design-Build approach, and our technologically advanced Warren Epoxy and Fiber Reinforced Polymer (FRP) system, were the most cost effective and durable solution for rehabilitating the deteriorated tank in a very short maintenance outage window, for a quick return to operational service. Our military grade Warren Epoxy is certified by the US Navy and the American Bureau of Shipping (ABS). It is also certified NSF-61 by the National Sanitation Foundation (NSF).

Quick Facts About the Historical & Successful Rehabilitation Project (but not limiting to):

1. Forty Nine (49) Years Old Potable Water Tank.
2. Three (3) Million Gallons Capacity (11,356,235 Liters).
3. Tank Height 32 Feet (9,75 Meters).
4. Floor Diameter: 128.5 Feet (39.2 Meters)
5. Floor area: 13,000 Square Feet (1,208 Square Meters).
6. Carbon Steel Tank Floor was rotten.
7. The Warren Epoxy Coating & FRP System Installation was about 20 times faster than the traditional Steel replacement (i.e. 5 Days Vs. 100 Days), and cheaper.
8. Applied Two Layers of Bi-Directional Composite Laminates. They covered a Total Area of about 26,000 Square Feet (2,416 Square Meters).
9. Composite Thickness of Flooring System was about ¼” (6.4 millimeters) thick.
10. First Potable Water Rehabilitation Project of its kind in the USA.
11. As of today, this tank is in excellent condition. Expected Useful Life is 50 Years.

The sewage reservoir was in semi deteriorated condition and with many leaking cracks and crevices. These latter contributed to active leaks (infiltration and exfiltration) that significantly contaminated nearby lakes and rivers.

PRODUCT APPLICATION

The surface preparation started with a high pressure wash with chemical solutions for initial removal of impurities; it was then rinsed with muriatic acid. A subsequent hydro-wash was performed with a mixed solution of chlorine and potable water for final rinse. Once the substrate surface was determined to be clean, all cracks were repaired using the Warren Epoxy product for manual application method with trowels. It should be noted other than the localized cracks, the substrate was generally in semi-deteriorated condition and able to receive the coating without the need for a sandblasting because the concrete substrate did have the required surface profile and tensile strength. All localized required structural repairs were carried out as planned, as well as the quality assurance inspections and tests, and with no safety issues. The Warren Epoxy was sprayed and the coating thickness was 1/8 “(3 millimeters).

CONCLUSION

Because the Warren Epoxy is a single coat application and a fast cure of less than 2 hours, the project was performed and returned to service at the end of the same work day. MADERO’s execution of this turnkey Mission Critical Project was a total succes.

New York City’s Downtown Manhattan Heliport is located at Pier 6 in the East River in Manhattan, New York. As many marine facilities, the facility presents very adverse conditions to a successful coating of steel in the tidal zone. Strong water currents near the shore apply significant force to the sides of the structures in the river. The force of the water current, especially during rising tides, can easily remove newly applied coatings. Before the application of Warren Epoxy on October 3rd, 2002, several marine epoxies, which had been applied successfully in the past under more quiescent water conditions, lost adhesion when applied to cleaned areas on the barge.

PRODUCT APPLICATION:

The barge’s west side was blasted cleaned to a near white metal condi- tion (SSPC SP 10 Warren Epoxy coating was applied with plural compo- nent spray equipment. The coating was applied from MHW (mean high water) to approximately 1 foot above MLW (mean low water).

CONCLUSION:

On June 10, 2003, an inspection by the owner (New York / New Jersey Port Authority) revealed that the Warren Epoxy coating was in very good condition, hard and intact with no loss of adhesion. No rusting was evident. The approximate coat thickness range of 20 – 30 mils was obtained, agreed with the original average thickness range of about 24 mils.

In July 2005, Warren Epoxy was applied to provide Corrosion Protection Rehabilitation to a Third Deck wing wall Ballast Tank. The tank’s inboard bulkhead was the well deck wing wall and the outboard bulkhead was the hull. The tank is located below the Ship’s laundry. There are ballast tanks located below the tank (5-121-1-W and 5-125-1-W). The tank is filled by the ship’s Salt Water Fire Main System and empties by way of a ballast valve.

Warren Epoxy is considered by the US Navy to be a Rapid Cure Single Coat Qualified Product. It has successfully passed the US Navy’s laboratory qualification process and shipboard in-service performance requirements in accordance with military specification MIL-PRF-23236, titled “Performance Specification, Coating Systems for Ship Structures”.

Furthermore, Warren Epoxy is also a Certified Coating Product by the American Bureau of Shipping (ABS) for application in their ABS approved Ships and Facilities.

PRODUCT APPLICATION:

The coating and surface preparation work took place during a scheduled maintenance and repair availability, also known as a Docked Phased Maintenance Availability (DPMA) at US Navy’s Norfolk, Virginia ship repair yard.

Requirements for the surface preparation work item were in accordance with the appropriate seawater ballast tank and potable water tank preservation requirements of the CORE PPI (rev 16) and NAVSEA Standard Item 009-32.

These requirements included:

• Initial cleaning and pressure wash to remove loose contaminants.
• Dehumidification was maintained throughout the surface preparation and coating application activities.
• Abrasive blasting for the establishment of a sharp angle surface profile, old coating and rust removal, was performed in accordance with Steel Structures Painting Council (SSPC) SP-10, Near White Metal.
• Ensured that conductivity levels were below 30 microSiemens/cm2.
• Removal of Chloride contamination.

After the surface preparation activity was completed, the Warren Epoxy coating was applied with plural component spray equipment; some localized areas were touched-up and stripe coated with brush and roller. All QA/QC inspections and testing were performed during the entire surface preparation and coating application activities.

CONCLUSIONS:

Warren Epoxy met the US Navy’s stringent requirement of a durable, technologically advanced and proven solvent free 100% solid epoxy for improved materials and process aimed at reducing maintenance and operating costs, repairs down time, and extending useful service life.

Furthermore, Warren Epoxy coating was inspected in March 2013 and after 7.5 years of service, it was found to be in Excellent Condition! and on-track for an expected long term service life.