ARC FOR CONCRETE PHOTOCASE HISTORY/PRESENTER · arc for concrete photocase history/presenter arc...

ARC FOR CONCRETEPHOTO CASE HISTORY/PRESENTER

ARC DIVISION OF CHESTERTON225 FALLON ROAD, MIDDLESEX INDUSTRIAL PARK, STONEHAM, MASSACHUSETTS 02180-9101 USA

TEL: (617) 438-7000 – FAX: (617) 438-8971 – TELEX: 94-9417 – CABLE: CHESTERTON STONEHAM, MASS.© A.W.CHESTERTON CO., 1994. All rights reserved.

® Registered trademark owned and licensed by A.W.CHESTERTON CO. in USA and other countries.PART NO. 073338 PRINTED IN USA 11/94

CAUTION:The material contained herein is for

training and demonstration purposes only.The photos are not intended to either show proper or improper use

of safety practices but to illustrate product application.

ARC® Composites for ConcretePrivate and Confidential. © A.W. CHESTERTON CO.,1994. All rights reserved.Part No. 073338

C O N T E N T S

TABLE OF CONTENTS

1 SPALL REPAIR

2 JOINTS AND CRACKS

3 SRS - SLIP RESISTANT SURFACE

4 PUMP BASES/PADS

5 CONTAINMENT AREAS

6 PROCESS AND WAREHOUSE FLOORS

7 TECHNICAL ANALYSIS■ Cost Overview■ Limitations of Concrete■ Limitations of Coatings■ Properties of an Ideal System■ ARC Meets These Requirements■ Sand Filled Epoxies vs. ARC Composites■ Summary of Unique Performance Characteristics

8 PRODUCT SELECTION■ Packaging■ Components and Product Styles

9 CASE HISTORIES

10 APPENDIXTRADITIONAL TECHNOLOGIES■ Acid Brick■ Fiberglass■ Sand Filled MMA■ Resin Rich Systems

1.1ARC® Composites for ConcretePrivate and Confidential. © A.W. CHESTERTON CO.,1994. All rights reserved.Part No. 073338

S P A L L R E P A I R

SPALL REPAIR

Minor Concrete Repairs (Spalls)Have Hidden Costs Which Are Often Overlooked.

THESE INCLUDE:■ The Cost toContinuously

Do The Same Repairs Over and Over.LaborMaterials - Patching Compounds.Inconvenience to Production.

■ Damaged Finished GoodsOne Example: Paper rolls would fall off fork lifts due to potholes and other flooring problems, costing as much as $1,000 U.S. dollars per day in damaged production.

■ SafetyA sprained ankle or other related work injury can cost, on average $28,000 U.S. dollars. Insurance and other costs rise.

CONCRETE PATCHING COMPOUNDS ■ Do not bond well to themselves - fail again quickly.■ They are weak and brittle in thin patch applications.

EPOXY PATCHING COMPOUNDS■ Do not bond well to damp or wet surfaces.■ Crack,are brittle, and are poor for impact.■ Shrink,disbond.■ Often create a slippery, dangerous surface.


S P A L L R E P A I R

ARC® COMPOSITES FOR CONCRETE

An Engineered Quartz Surface To Eliminate Spalls And Their Associated Costs

■ Safe and easy to use.■ Bonds well to all concrete surfaces…even damp or wet.■ Adhesion stronger than concrete.■ Extremely impact resistant.■ Non-shrinking.■ Provides slip resistant surface…even when wet.■ Eliminates costs due to:

Continuous repairs.Injuries due to spallsProduction losses.

■ ISO 9001 Quality Certified.■ Complete training and support to maintenance personnel.■ USDA authorized.■ Provides 100% permanent spall repair.


S P A L L R E P A I R 1.3

PCC 5031

MAJOR LEAGUE INDOOR STADIUM USA

1. Outside view of sports arena.

2. Severe settling of asphalt and spalling of concrete leftan uneven surface whichcould cause major leagueathletes to sprain their ankles.Also, heavy equipment usedfor maintenance, breaks apart previously used repairproducts which lasted only 3-6 months.

3. After priming, ARC® 790 wasapplied to spalls and unevensurfaces, providing an even,smooth and impact resistantsurface. Entire applicationwas performed quickly during conversion from baseball to football field.



PCC 5036

HYDRO ELECTRIC POWER PLANTUSA

1. Critical areas of concretebraces subjected to erosion and freeze/thaw cycling, created spalling and degradation at this power plant.

2. Close up view of spalls showing exposed re-bars.

3. A view of surface preparationundertaken on working platforms.

ARC® Composites for ConcretePrivate and Confidential. © A.W. CHESTERTON CO.,1994. All rights reserved.

Part No. 073338

1.5 S P A L L R E P A I R

4. A close up view of some of the more severely eroded/ spalled areas of the braces.

5. A general view of theapplication conducted on the severely damagedbraces.

6. A close up view of a repairedspall with ARC® 791V. After more than 3 years in service, the repairs are in perfect condition. In other independent tests in Northern regions, ARC 791V and 791H were successfully subjected to112 freeze/thaw cycles.

PCC 5036



PCC 5042

INDUSTRIAL WAREHOUSEBoston, USA

1. Concrete stairway, constant-ly in use, experienced typicalspalling and degradation dueto environmental conditions.

2. Heavy spalls were saw cut and mechanically abraded.

3. View of saw cut, squared-off-nose step, ready forpriming with ARC® 797.


Part No. 073338

1.7 S P A L L R E P A I R

PCC 5042

4. The area was masked withduct tape prior to priming, to insure a clean and perfect finish, rebuilding only the area prepared.

5. View of completed spallrepair with ARC 791V.

Note: ARC Quartz Composites provide an excellent slip resistantsurface due to its identicalcoefficient of friction on wet or dry surfaces.


J O I N T R E P A I R 2.1

JOINT REPAIR

Typically The Most Demanding Area Of A Concrete Floor Is At The Expansion Joints:

■ The joint nosing is subjected to severe impact.■ The concrete cracks, causing uneven surfaces.■ Patches are poorly designed, they crack and fail rapidly.■ Associated Costs Includes:

Constant repairFinished goods are damaged due to “jarring” of fork liftsInjury due to unsafe working conditions for forklift operatorsInterruption to production process (during repairs)due to sealed off areas


J O I N T R E P A I R 2.2


The ARC Expansion Joint System Provides The Desired, Or Required, Impact Resistant Expansion Joint

Composite

2 Component flexible sealantcapable of (± 50% joint movement)

Non gassing, non water absorbing backer rod

40 mm (1.5") 40 mm (1.5")

■ Provides as much as10 times the impact resistance of concrete, excellent for steel wheels.

■ Allows for expansion and contraction without cracking■ Maintains a permanent, level surface

(no bumps) for fork lifts.■ Eliminates the cost associated with

frequent repairs (labor and production)■ Safe and easy to apply■ ISO 9001 Quality Certified■ USDA authorized■ Complete training and support to maintenance personnel


S L I P R E S I S T A N T S U R F A C E S

SLIP RESISTANT SURFACES

Conventional Methods of Providing Slip Resistant Surfaces Generally Do Not Provide Long Term, Reliable Service, Creating Frequent Repairs and Unnecessary Expense.

DISADVANTAGES OF OTHER SYSTEMS COMPARED TO ARC-SRS:

TapesPeel easily & create tripping hazards.Adhesive fails in damp or wet applications.Quickly wears smooth, losing it’s grip.Catch and tear when equipment is dragged over it.

Paints Mixed with SandWear smooth quickly, the painted surface is then very slippery.Scratches when equipment is dragged over them.Have poor chemical resistance.Sand fractures under a person’s weight.

Epoxy or Polyester with Sand, Flint or GritMost shrink on cure and tend to peel off.The sand or grit tends to pull out of the polymer binder (the epoxy or polyester) because they aren’t formulated with special additives intended to bond to ceramics.The binder is easily worn out since it does not contain ceramic reinforcements.Low quality formulations provide marginal adhesion and become brittle with age.Flint is a fire hazard.


S L I P R E S I S T A N T S U R F A C E S 3.2

ARC® SLIP RESISTANT SURFACE (SRS)

■ Wears longer than conventional systems■ Will not peel or delaminate■ 5 years in fork lift, 7 years in foot traffic (minimum)■ Reduce escalating insurance costs■ Reduce lost-time accidents ■ Excellent chemical resistance■ Does not age or become brittle■ Easy handling and application characteristics



PCC 5018

PULP AND PAPER INDUSTRYKraft Mill, Southeastern, USA

A major container corporationwas experiencing damp andslippery surfaces in their warehouse. Spinning wheelsand poor braking resulted in unsafe conditions for fork lift operators.

1. The area was first cleanedwith ARC® specified cleanersand then masked with ducttape.

2. ARC SRS (Slip ResistantSurface) was applied. Duct tape was removedimmediately after applicationand the ARC SRS allowed to cure.

3. The finished area is resistantto most industrial chemicalsand will last in severe fork lifttraffic for up to 5-7 years.



PCC 5019

PAPER MILLLouisiana, USA

Ramp from warehouse to rail car loading area would getdamp and slippery, creatingunsafe conditions. Fork liftswould slip, endangering theoperator and damaging product.

1. The area was first cleanedwith ARC® specified cleaners.

2. The area was masked with duct tape, followed by an application of ARCSRS (Slip Resistant Surface)and then the duct tape was removed.

3. After ARC SRS had cured,excess abrasive wasremoved.

Result: After 18 months in service, ARC SRS is in perfect condition.

Expected Life: 3-5 years.



PCC 5024

OUTDOOR WAREHOUSE RAMPUSA

Rain, combined with dirt andgrease, created an extremelyslippery surface for fork lifts.The permanent solution wasto coat the ramp with ARC®

SRS (Slip Resistant Surface)to stop the fork lifts fromskidding.



PCC 5017

WATER TREATMENT FACILITYCorpus Christi, Texas

1. ARC® SRS (Slip ResistantSurface) applied to the top of Phosphoric Acid holdingtanks. Previous non-slip systems last 6 months. (Tank on right shows failedadhesive backed tape andfiberglass panels).

2. After tank top on left wasblasted, ARC SRS was applied in a striped pattern.

3. In January 1994 a purchaseorder was received for a second tank top.



PCC 5021

CHEMICAL PLANTSan Antonio, Texas

Floor and walkway adjacent to mixing tanks are often wet and slippery. ARC®

SRS (Slip Resistant Surface)was applied to eliminate theproblem. Work performed by the plant maintenancepeople.



PCC 5022

WATER TREATMENT PLANTMission, Texas

1. Outside stairwells were often wet, creating a slippinghazard. Conventional “non-slip tapes” continually peeled off, so ARC® SRS (Slip Resistant Surface) was applied to eliminate the hazard.

Expected Life: 12-15 years.



PCC 5023

WORLD’S LARGEST MANUFACTURER OF CONSUMER ELECTRONICSSan Antonio, Texas

A ramp at this facility became extremely hazardouswhenever it rained or becamewet from condensation.

The photos show ramps withARC® SRS (Slip ResistantSurface) applied, thus eliminating the hazard.

Result: Eliminated accidentsand product damage fromslipping fork lift tires.



PCC 5025

HIGH SCHOOL FOOTBALL STADIUMSan Antonio, Texas

1. Problem: Slip resistant tapeswould continually wear outeach season (shown in photo 1). To test the performance of ARC® SRS(Slip Resistant Surface), itwas placed along side a newpiece of slip resistant tape.

2. This photo illustrates the dramatic results of the sideby side evaluation. Note howthe tape wore off, and theARC SRS is in perfect condi-tion, after nine months.

Expected Life: 12 -15 years.



PCC 5026

WASTEWATER TREATMENT PLANTSan Antonio, Texas

ARC® SRS (Slip ResistantSurface), used on ladders to prevent falling.



PCC 5027

AQUATIC PARKSan Antonio, Texas

ARC® SRS (Slip ResistantSurface), used on platforms to prevent slipping.



ARC® SRS (Slip ResistantSurface), used on piping wherepeople must stand to reachcontrol valves or to read sight gauges.

ARC® SRS (Slip ResistantSurface), used on floor at doorway entrance.

PCC 5028

PAPER MILL USA

PCC 5029

SPORTS ARENA ENTRANCEUSA


P U M P A N D E Q U I P M E N T P A D S 4.1

PUMP AND EQUIPMENT PADS

One of the Most Critical Functions Of Concrete In Industry is to Provide a Strong Base For Pumps and Other Equipment.

EPOXY GROUTS, FIBERGLASS AND OTHER COATINGS OFFER ONLYTEMPORARY “PATCH” REPAIRS AND ARE UNRELIABLE■ Many are unsafe to use or apply■ Due to sagging, most require cumbersome forms to make repairs■ They are an ineffective chemical barrier and often only masks the problem■ Poor adhesion to damp or contaminated concrete

CONCRETE■ Is weak and brittle■ Has poor chemical resistance■ As a repair material, it has poor adhesion to itself

FAILURE OF PUMP BASES AND CONCRETE PADS CAN LEAD TO HIGH COSTS:■ Downtime for repairs■ Excessive vibration resulting in failures

of bearings and mechanical seals■ Chemicals contaminate concrete, soil and ground water■ Equipment settling or misaligning resulting in mechanical

failures




A Permanent, Reliable Technology for Building or Reconstructing Pump Bases

■ Tough, resilient quartz composite, resists and dampens vibration and its affects

■ Eliminates future repairs of pump bases, reduces failure of mechanical seals, gaskets and flanges

■ Non-sagging formulation allows for ease of application to vertical surfaces (virtually eliminates time and cost of forming)

■ Chemical resistance and reliability surpasses all conventional coatings

■ ISO 9001Quality Certified■ Tenacious adhesion to damp, real life applications■ Complete training and support to maintenance personnel



PCC 5020

WATER TREATMENT FACILITYCorpus Christi, Texas

1. Pump base and adjacentarea were attacked byPhosphoric Acid and Alum.The surrounding area wasconstantly wet and slippery.

2. ARC® 988V was used torepair and protect the pumpbase.

3. ARC SRS (Slip ResistantSurface) was installed in the adjacent area to protectworkers from slipping.



PCC 6008

CHEMICAL PROCESSING PLANT

1. Large concrete floor areawas severely contaminatedand degradated by continuous spillage of Sodium Hydroxide (NaOH).

2. Following high pressurewater blasting, ARC® 797Hydrophobic primer wasapplied, followed by 6mm(1/4") thickness of ARC 791Vcomposite.

3. View of monolithic, encapsulated area ready for anchoring of pumps to their bases.

Note: Application performed in1989, is still in operation today!



PCC 6013

EXPLOSIVES PLANTPortugal

Area: Pump bases operating inarea of demineralization.

Problem: Severe degradationof cement due to chemicalattack.

Solution: After cleaning contaminated concrete, pumpbase is primed with ARC® 797and rebuilt with 6 mm (1/4") ofARC 791V quartz composite.

View of perfectly rebuilt pump base ready for pumpassembly. Due to its excellentperformance, all pump basesat this plant were rebuilt andprotected with ARC 791V.



PCC 5039

CHEMICAL PLANTHouston, Texas

1. Pump base severely erodedfrom 20% HCl acid attack.Surface preparation included346 Descaler and ChemicalCleaner and fresh waterrinse.

2. ARC® 791V applied to base.Wood forms, coated withrelease agent, were used to hold product in place until cured.

3. Wood forms removed. 5 x19 Kg kits were applied to pump base.


C O N T A I N M E N T A R E A S 5.1

CONTAINMENT AREAS

Concrete Containment, Including Secondary Containment, Is Today One of Industries’ Main Concerns and Potentially Its Greatest Liability.

■ CONCRETE IS EXTREMELY POROUS AND IT’S NOT DESIGNED TO CONTAIN OR RESIST AGGRESSIVE CHEMICALS AND SOLVENTS.

■ TRADITIONAL COATINGS ARE NOT RELIABLE BECAUSE OF THE FOLLOWING:

Some are non-monolithic.They crack and delaminate.Independent tests have concluded that thin film systems cannot offer reliable protection against acids because they exhibit porosity.

■ Specified by engineers for more aggressive and demanding applications.

■ Pre-encapsulated, pre-engineered quartz reinforcements offer high density, cross linking properties which virtually deter permeability of chemicals to the concrete substrate.

■ Closely matches the thermal coefficient of expansion for concrete (prevents delamination).

■ Ultimate chemical resistance properties, even in long term immersion conditions, outperforms all competitive systems.

■ Excellent adhesion to damp, severely exposed, damaged concrete surfaces.

■ ISO 9001 Quality Certified.■ Complete training and support to maintenance personnel.




ARC Offers a Proven System When Specifications Call For a Long Term Solution to Concrete Containment, As Well As Secondary Containment.



PCC 6000

WASTE CHEMICAL BASIN STEEL PLANTJapan

1. Concrete is attacked bycaustic soda and otherwaste chemicals at this steel plant.

2. The surface was cleanedwith water blasting.


Part No. 073338

5.4 C O N T A I N M E N T A R E A S

PCC 6000

3. View of application surfacenearing completion.

4. Completed waste tank readyfor service.

Product: ARC 791VArea: 100 m2 (1,100 ft2)Chemical: NaOH and otherwaste chemicalsTemperature: AmbientDate of Installation:November 1992Current Condition: Excellent



PCC 6001

SECONDARY CONTAINMENTCHEMICAL PLANTJapan

1. New containment area is to be subjected to high concentrations of Sulfuric Acid.

2. The new concrete wasallowed to cure 30 days and then prepared prior to providing a monolithic protection with ARC®.

3. ARC 791V was applied overthe newly installed secondarycontainment area. View oftank base encapsulated withARC 791V and application tocontainment wall in progress.


Part No. 073338


PCC 6001

4. View of acid containmentarea and tank pad, nearingcompletion.

5. View of finished containment,ready for tank assembly.

Product: ARC 791VArea: 40 m2 (400 sq. ft.)Chemical: H2SO4Date of Installation: March 1992Current Condition: Excellent



PCC 6009

LARGE REFINERYJapan

1. Containment walls for overflow of 70% Sulfuric Acid (H2SO4), causes rapidfailure to previously usedresin-rich epoxy product.

2. After following ARC surfacepreparation procedure, which included completeremoval of failed product, the overflow containmentarea was rebuilt with ARC® 791H.


Part No. 073338


PCC 6009

3. A view of another area whichwas also rebuilt, providing a positive containment area from overflow of 70% Sulfuric Acid.

Note: Application performedin September 1990 and is still operating today. Since then,most containment areas, as well as concrete wastetanks, have been protectedwith ARC Quartz Composites.


P R O C E S S A N D W A R E H O U S E F L O O R S 6.1

PROCESS AND WAREHOUSE FLOORS

Industry Is Well Aware That the Efficiency Of Its Production Equipment and Its Manufacturing Process is Critical to Competitiveness andProfitability. The Floors in These Manufacturing,Process and Warehouse Areas Are An Integral Part of Manufacturing.

■ Floors with defects can hinder scheduled production and in some cases, damage finished product.

■ The continuous need to repair these floors, not only interferes with production but often brings production to a complete halt.

■ Dust created during repairs can contaminate finished goods.

When all these costs are analyzed, they justify the use of the best, most reliable, flooring technology rather than products which initially appear cheaper per square meter (sq. ft.).


P R O C E S S A N D W A R E H O U S E F L O O R S

PROCESS AND WAREHOUSE FLOORS

Through Experience, Industry Has Found That Conventional Floor Coatings Require Frequent Repairing Due to the Following Performance Limitations:

■ Thermal expansion is incompatible with concrete which results in various degrees of delamination and cracking.

■ Epoxy or resin formulations allow rapid chemical permeation.

■ Poor adhesion to damp or contaminated concrete.

■ Blistering, peeling and delamination.

■ Slippery surfaces cause a hazardous work environment for employees and fork lift operators.

■ Low mechanical properties do not provide desired or required impact resistance.


P R O C E S S A N D W A R E H O U S E F L O O R S


ARC Engineered Composites Offer the Most Economical Flooring Technology in the World.

■ Independent testing and proven applications confirm ARC’s reliability and performance above all traditional coatings.

■ Matches thermal expansion of concrete.■ Dense packing quartz reinforcement virtually deters

permeability and provides unrivaled chemical resistance.■ Low viscosity, hydrophobic primer provides tenacious bond

to all types of concrete surfaces, including damp or chemically contaminated concrete.

■ Safe to use, easy handling characteristics.■ Provides even floor surface for moving equipment.■ Proprietary technology yields a slip resistant surface

with the same coefficient of friction, wet or dry.■ Excellent impact resistance, will not spall.■ USDA authorized.■ ISO 9001 Quality Certified.■ Complete training and support to maintenance

personnel and contractors.



PCC 5041

PAPER MILLUSA

1. The floor adjacent to the paper machine was rough and unsafe. After pre-surface preparation,major cracks were "V" cutand repaired with ARC® 791V.

2. ARC 791V is screeded intoposition using a magnesiumscreed bar. Screed guidesare used with the screed barto achieve proper productthickness.

3. ARC 791V is finished to provide a level floor.

Area: 215 m2 (2300 ft2)Note: After 41/2 years in service,the floor is in perfect conditionwith no spalls or cracks.



PCC 5038

FOSSIL POWER PLANT SCREEN WASH HOUSE New York, USA

1. Concrete floor of screenwash house was severelyeroded by salt water, silt and other contaminants.The surface was first prepared by scarifying. This photo shows primingwith ARC® 797 HydrophobicPrimer.

2. View of “assembly line” typeof application procedure:priming (above), mixing ARC791V and application.

3. ARC Quartz being mixed,and application commences.


Part No. 073338

6.6 P R O C E S S A N D W A R E H O U S E F L O O R S

PCC 5038

4. Further application, via handtrowelling, of ARC Quartz at6 mm (1/4") thickness asspecified.

5. Close up view of completedapplication which took 94system kits of ARC 791V torebuild 415 m2 (4,500 ft2) ofconcrete floor.

6. Another view of rebuiltscreen wash house floor.



PCC 5015

MANUFACTURERUSA

1. Damaged aisles slowed production at this manufac-turing facility. The floor was prepared by scarification.

2. ARC® 791H was applied, via screed box, and thenepoxy power troweled to a 6mm (1/4") minimum thickness.


Part No. 073338


PCC 5015

3. A smooth, flat floor wasachieved by utilizing thepower trowel.

4. Application was completedin the summer of 1989 and is still in service, providingan efficient and safe flooringsurface. Production is nolonger hindered by anuneven floor.



PCC 5030

MAJOR SOFT DRINKMANUFACTURERUSA

1. Due to chemical attack, concrete floor was severelydamaged.

2. After priming was completed,ARC® 791H Red is easilyapplied by hand and power trowels.

3. Finished view of completedaisle way.


Part No. 073338


PCC 5030

4. View of process area showsresistance to acid and caustic spills.

5. ARC 791H in service overfour years, outperforming all previously utilized flooring systems.



PCC 5035

MAJOR CHEMICALPROCESSING PLANTOntario, Canada

1. Concentrations of Sulfuric Acid (H2SO4) ranging from 60- 98%, destroyedpreviously used sand filledepoxies (SIKA®), thin filmedcoatings,vinyl esters and other resinous products and attacked the concrete.Continuous repair with thesetraditional products lasted only6 - 9 months. Sulfuric acidpermeated the concrete allowing contamination ofground water, and due to strict government regulations,created an environmental concern for the plant.


Part No. 073338


PCC 5035

2. Another close up view ofdestroyed sand filled epoxyand exposed concrete.

3. View of surface preparationusing high pressure waterblasting to remove failedproduct, clean and etch concrete.



PCC 5035

4. View of area after waterblasting and cleaning.

5. Following priming with lowviscosity, hydrophobic primer,ARC® 791H and ARC 791Vare applied using hand trowels.


Part No. 073338


PCC 5035

6. General view of large chemical containment area being completed.

7. Overhead view of another acidarea being protected.

8. On-going review, evaluationand supervision is conduct-ed to insure written ARCapplication specifications are followed.



PCC 5035

9. View of satisfactory completion of a containment area.

ARC was the only technology which workedsatisfactorily after five yearsin operation and without failure. The plant uses ARC exclusively to repairdamaged concrete throughout its large chemical complex.

10.View of ARC 791V used torebuild support bases andpads, which were severelyattacked by acid.

ARC has saved this plantseveral hundred thousandU.S. dollars in repair costssince 1989.

11. A close up view of a support base and generalarea protected from acidspillage.


Part No. 073338


PCC 5035

12. Another large containmentarea being prepared for an ARC application.

13.Close-up of a resin richepoxy product which failedwithin one year in a 60%Sulfuric Acid (H2SO4)containment area.

14. View of containment areabeing rebuilt, complete withpitch to drain, followingARC written specification.



PCC 5035

15. Overhead view of containment area beingcompletely encapsulated to prevent sulfuric acid(H2SO4) from attacking concrete.

16.Critical spillage area of 98%Sulfuric Acid (H2SO4) mustbe repaired and protected.

17. Heavy spillage area is protected with 6mm (1/4")thickness of ARC 988V.



PCC 5040

SPECIALTY PAPER MANUFACTUREROhio, USA

1. The main aisle way betweenthe two paper machines has deteriorated, resulting in the collection of water and chemicals to create anunsafe working condition.Shown here is a screed barset up to level and slope thefloor with ARC® 791V.

2. The floor is first cleaned byBlastrac®. Then joints aretaped and ARC 797 Primer is applied by roller.

3. ARC 791V is raked out andscreeded level.


Part No. 073338


PCC 5040

4. Close up of screeding process.

5. Using this process, an areaof 2.2 m x 3 m (7 ft. x 10 ft.)is applied in just 35 minuteswith four workers.

6. The area is finished usingmason trowels.

Note: After 4 1/2 years in service, the floor is inexcellent condition. Thereare no cracks or spalls.


T E C H N I C A L A N A L Y S I S

HIDDEN COSTS

Concrete And Floors

DAMAGEDCONCRETE

■ Safety Related Costs■ Environmental Costs

ComplianceClean UpFines

■ Production Losses■ Damaged Finished Goods■ Process Interruption■ Structural Damage to Equipment■ Building Depreciation■ Repair/Maintenance (Up Keep)



LIMITATIONS OF CONCRETE

POROUS - ALLOWS CHEMICALS TO MIGRATE■ Contaminates

Soil and Ground Water■ Attacks Structures,

Pipes And Cables■ Corrodes Reinforcing Bars

POOR CHEMICALRESISTANCE■ Light Acids■ Salts■ Strong Caustics

MODERATE PHYSICAL PROPERTIES■ Low Impact Resistance■ Chips and Cracks

H2SO4

Na2CO3NaOH HCL

H3PO4

H2SO4

Na2CO3NaOH HCL

H3PO4

H2SO4, H3PO4, NaOH, HCL, NaCO3H2SO4, H3PO4, NaOH, HCL, NaCO3



LIMITATIONS OF TRADITIONAL COATINGS

SEALERS

PAINTS

HIGH BUILD,GLOSSY,RESINSYSTEMSTypically 1-3 mm (30 mils - 1/8") thick

SCREED AND TROWELSYSTEM6 mm (1/4") and Above

■ Do not provide concrete with true chemical resistance■ Limited aesthetics■ No improvement to mechanical properties■ Can be slippery

■ Scratch & peel easily■ Do not provide concrete with true chemical resistance■ No improvement to mechanical properties■ Can be slippery

■ Inconsistent performance as a chemical barrier■ Cracks, peels and delaminates■ Incompatible thermal coefficient of expansion■ Limited mechanical protection - too thin■ Can be slippery

■ Poor adhesion, especially to wet surfaces■ Cracks and delaminates due to

incompatible thermal coefficient of expansion■ Field batching by contractors and the use

of common silica sand, result in:Low mechanical propertiesUnreliable chemical resistanceDifficult handling

7.4

3 mm (1/8")

6 mm (1/4")



PROPERTIES OF AN IDEAL FLOORING SYSTEM

■ High Adhesion to Damp Surfaces

■ Chemically Compatible With the Intended Service

■ Monolithic - No Seams, No Joints

■ Matched to Thermal Expansion of Concrete

■ No Shrinkage

■ Nonporous

■ Easy to Install

■ Resistant to Impact and Cracking

■ Minimum 6 mm (1/4")

In Impact: As the thickness of a coating increases, the shock per unit areadecreases exponentially



ARC COMPOSITES MEET ALL OF THESE REQUIREMENTS AND MUCH MORE…

■ ISO 9001 Certified■ Provides a Global Network of

Technical Service and Field Support■ Proven by Many Independent Tests

to Offer the Best Flooring Technology

INDEPENDENT TESTS

Major pulp & paper producer tested 14 different epoxy floor coatings and commissioned a 2 1/2 year civil engineering study into floor coatings. Their criteria included:

1. Durability2. Safety3. Coefficient of thermal expansion

ARC TECHNOLOGY WAS RATED #1 IN ALL THREE CRITERIA:1. Unmatched impact resistance2. Excellent and identical slip

resistance wet and dry3. It’s thermal coefficient of

expansion most closely matched concrete

Worlds’ largest producer of copper evaluated numerous floor coatings for immersion in sulfuric acid.

BASED ON THOROUGH EVALUATION, ARC WAS SELECTED AS THE MATERIAL OF CHOICE.

Los Angles County Waste Water TreatmentDistrict, tested 61 different concrete coatingtechnologies. All were specified and applied by the coating manufacturers. 51 failed within 6 months of exposure.

ONLY 10 PRODUCTS PASSED THE TEST, ONE WAS THE ARC COMPOSITE.

ARC WAS THE ONLY ONE WHICH PASSED EVALUATION.

Major dairy plant in Europe evaluated 10 flooring technologiesagainst lactic acid.


T E C H N I C A L A N A L Y S I S 7.6

ENGINEERED QUARTZ REINFORCED COMPOSITE

VOLUME RATIO: 7 PARTS QUARTZ TO 1 PART EPOXY■ Smooth surfaced quartz

requires minimum resin■ Prewet with coupling

agent eliminates air voids, providing complete bonding between the quartz particles

■ A range of high performance resins to resist most industrial chemicals.

RESULT: MAXIMUM PACKING OF THE REINFORCEMENT■ Lowers the coefficient

of expansion -closely matching concrete

■ No cracking or disbondmentby thermal cycling

■ Low exothermic heat■ No appreciable shrinkage

POLYMER MATRIXCOUPLING AGENTQUARTZ REINFORCEMENT

■ Air voids inhibit dense packing of sand and minimize adhesion

■ Rough sand surface requires excessive resin

PROBLEM: ■ Differences in thermal

coefficient of expansion cause cracking and disbondment

■ Higher exothermic heat,higher shrinkage


T E C H N I C A L A N A L Y S I S 7.7

TYPICAL SAND FILLED RESIN - FAIL OFTEN

VOLUME RATIO:3 PARTS QUARTZ TO1 PART EPOXY

VOLUME RATIO: 7 PARTS SAND TO1 PART EPOXY

Without Proper Engineering a 7 to 1 ratio will:■ Have Excessive Air Voids■ Have No Cohesive Strength■ Be Porous

TO MATCH THERMAL COEFFICIENT OF CONCRETE REQUIRES

EPOXYAIRSAND



POLYMER QUARTZ COMPOSITES:PRIMARY FEATURES

PRIMER

RESULT

■ Low Viscosity

PENETRATES…Concrete Surface

■ Hydrophobic DISPLACES…Moisture on Surface

■ Moisture Insensitive

CURES…In Presence of Water

■ Excellent Adhesion to Damp Concrete■ Tolerant of Application Conditions■ Provides Reliable Adhesion

in “Real Life” Conditions



QUALITY

Awarded the ISO 9001 Quality Standard February 25,1993

NATIONAL STANDARDS AUTHORITY OF IRELANDGLASNEVIN, DUBLIN 9, IRELAND

Certificate of Registrationof Quality System to

I.S./ISO 9001 / EN 29001:1989The National Standards Authority of Ireland certifies that

A.W. Chesterton CompanyStoneham, Massachusetts, USA

has been assessed for compliance with the provisions of the aboveIrish Standard in respect of the scope of operation given

hereunder and is hereby registered in theNational Register of Certified Products and Registered Companies.

Scope of Registration

design, and manufacture of mechanical seals, components, spare parts, repairsand exchange; pumps and pump related products, components, spare parts

and repairs; industrial maintenance products and polymer composites;hydraulic & pneumatic sealing devices and affiliated products at

Groveland, MA, USAdesign and manufacture of mechanical packing, gasketing and

affiliated live loading products at Woburn, MA, USA

The technical requirements of the standard referred to above are identical to the following nationalstandards harmonized with EN 29001:France NF-EN 29001, Germany DIN ISO 9001,

United Kingdom BS 5750: 1987: Pt 1, USA ANSI/ASQC Q91 and also the national standardsImplementing the ISO 9000 (EN 29000) series in the other countries of the EC. EFTA and worldwide



SUMMARY OF UNIQUE PERFORMANCE CHARACTERISTICS

1 Adhesion to Damp Surfaces

2 High Impact & Compressive Strength■ Physical Properties 3X Standard Concrete

4 Thermal Coefficient of Expansion■ Closely Matches Concrete

5 Minimal Shrinkage

6 Same Coefficient of Friction (Slip Resistance) Wet/Dry

Outstanding Chemical ResistanceACIDS■ Sulfuric (H2SO4): 0 -98%■ Hydrochloric (HCL): 0 -37%■ Nitric (HNO3): 0 -20%

CAUSTICS■ Sodium Hydroxide (NaOH): 0 - 50%

SOLVENTS■ Gasoline■ Ketones■ Xylene■ Chlorinated Hydrocarbons

3

8.1

SELF CONTAINED KIT (19KG KIT)


P R O D U C T S E L E C T I O N

ARC® PACKAGING

IDEAL FOR:■ Daily Repairs■ Do It Yourself■ Spalls/Joints■ Pump Bases■ Emergency Repairs

Coverage:1.4 m2 (15 sq. ft.) at 6mm (1/4")

SCHEDULED MAINTENANCE (SYSTEM KIT)

IDEAL FOR:■ Larger Projects■ Floors■ Containment Areas

Coverage:4.1 - 4.6 m2 (45 -50 sq. ft.)at 6mm (1/4")

8.2

DIVISION OF CHESTERTON®®



QRVOR

QRH


A A B

(1) (2) (3) (4) (5)


B

ARC 790

ARC 791V

ARC 791H

ARC 988V

PRODUCT STYLES

BOTH SYSTEMS CONSIST OF FIVE COMPONENTS


P R O D U C T S E L E C T I O N

THE ARC® SYSTEM

PRIMER TOP COATQUARTZ

REINFORCEMENT


C A S E H I S T O R I E S 9

PCC 6005

PAPER MILLNew Zealand

Concrete chlorate tank is subjected to severe chemical attack requiringfrequent repairing andpatching. ARC 791V wasspecified to give a long termprotection to the entire tank.



PCC 6002

BEER BREWERYJapan

1. A chemical pump to supplyDEOXIDIZER into a waterline of heat exchanger forprevention of scale build up on pipe surface.

The DEOXIDIZER, NaHCO3is very aggressive againstconcrete and attacks thesurface as shown.

2. Note the completely degradated concrete at base of chemical pump.


Part No. 073338

9 C A S E H I S T O R I E S

PCC 6002

3. View of concrete pump padrebuilt with ARC 791H.

4. Another view of perfectlyrebuilt pump pad.

Product: ARC™ 791HArea: 10 m2 (100 sq. ft.)Chemical: NaHCO3, Sodium BicarbonateDate of Installation: June 1993Current Condition: Excellent



PCC 6003

PIERSouthern Italy

1. This pier, used to bring in salt water for Europe’s largest salt plant, was affected by salt water, air and humidity duringhigh/low tide fluctuations.


Part No. 073338


PCC 6003

2. The concrete support struc-ture was subjected to ero-sion conditions, as well asdegradation from salt, whichingressed into the concreteand corroded the reinforce-ment bars, threatening theoverall integrity of the entirepier.



PCC 6003

3. After removal of loose concrete, the reinforcing bar was abrasive blasted tonear-white metal. The entirearea was then primed andmolds were used to applyARC® 790.


Part No. 073338


PCC 6003

4. ARC 791V was applied by hand trowel to provide a sealed surface to permanently eliminate theingress of the salt water.

5. Typical column after repairwith ARC PolymerComposites.



PCC 6006

MAJOR PAPER STOCK PLANTPORTUGAL

1. Screw pumps used to lift theeffluent into water treatmentponds. The pH can varydepending on the effluent.The concrete sleeves werecorroded, resulting in loss ofpumping efficiency. Thethree pumps were runningalmost continuously to keepup with the effluent, resultingin major cost in electrical (kW)consumption.

2. The damaged areas of thepump troughs were restoredwith rapid setting concrete,then resurfaced with 10.5system kits of ARC® 791V.


Part No. 073338


PCC 6006

3. A suitable mixer wasunavailable, so ARC 791Vwas mixed easily with shovels in a trough.

4. After priming the concrete,ARC 791V is easily trowledinto the near vertical surface.



PCC 6006

5. The non-slump nature ofARC 791V, and ease withwhich it is troweled, madethe application go quickly.

6. All three pump troughs were successfully rebuilt and protected in one day.


Part No. 073338


PCC 6006

7. Shown the following day,ARC 791V is ready forreassembly of the pump.

8. The screws being installedjust 18 hours after ARC 791Vwas applied.

Result: After nearly one yearin service, ARC 791V is perfect.The efficiency has increased to the point that now only onelift pump is required, instead of four. This has proved to bethe biggest savings, due to adecrease of 66% in electrical(kW) consumption.



PCC 5032

MAJOR LEAGUE INDOOR STADIUM FACILITYUSA

1. Concrete section for accommodating fans attending stadium eventswas severely damaged byimpact. Phosphoric acid,from soft drink spillage, also degradated concreteand corners on step edges.

2. Previous attempts to repairwith conventional productsled to disbondment and didnot provide a solution tochemical attack.

3. A close up view showing theforming procedure used toproperly rebuild vertical surfaces with ARC® 791V.This provides excellent bond-ing to existing concrete, aswell as resisting phosphoricacid (Coca-Cola, Pepsi).

Note: Areas rebuilt againstsoda spillage did not requireforming.



PCC 6010

EURO DISNEY®France

1. Steel wheels of carts, which carry riders on theSnow White ride, severelydamaged the concrete floor.The damage from abrasionleaves an uneven floor surface, causing possiblesafety problems and oftenresulting in “shut downs”.After an initial test area withARC® 791H proved success-ful, the management of theamusement park decided torebuild, with ARC, the entireride track covering 600 m2

(6,600 ft2).


Part No. 073338


2. Surface preparation includedscarification of the concrete,cleaning (vacuum) and priming with ARC 797.

PCC 6010



PCC 6010

3. View of area being vacuumed after scarification.

4. Partial view of the trackrebuilt with 6mm (1/4")thickness of ARC 791H. This curved area was one of the most affected areas,due to the sharp turning of the steel wheels on concrete.


Part No. 073338


5. A close-up of the rebuilttrack.

6. A general view of the paralleltrack ready for long termservice and fun.

PCC 6010



PCC 6004

WASTE WATER TREATMENT FACILITYSpain

1. Waste Water clarifiers at amunicipal water treatmentfacility.

2. The concrete rim around the clarifier is experiencingspalling of the concrete dueto freeze/thaw cycling andwear from rollers with loadsup to 5,000 kg (11,000 lbs.).

3. Rubber rollers used for thesweeping arm of the clarifierare destroyed and need tobe frequently replaced dueto the roughness of thespalled concrete.


Part No. 073338


PCC 6004

4. ARC® 791 is installed around the entire perimeterof the track.

5. Guide strips are used during the installation of theARC Polymer Composites to insure that the surface iseven and flat.



PCC 6012

EXPLOSIVES FACTORYPortugal

Area: Drainage area of acid tanks.Problem: Degradation ofcement, caused by chemicalattack from a mixture of sulfuric acid (H2SO4) and nitric acids (HNO3), water and organic acids.Solution: Rebuilt and protected with ARC® 988V,monolithic, ultra-chemicalresistant quartz composite.



PCC 6011

CHEMICAL PLANT

1. Concrete pump bases protected with acid resistanttiles, disbond from substratedue mainly to permeability of70% concentration ofSulfuric Acid (H2SO4).

2. The tiles allow acid to permeate at the joints thus leading to a rapiddegradation of the concrete.


Part No. 073338


PCC 6011

3. After removal of acid tilesand contaminated concrete,pump bases were rebuiltwith ARC® 988V, the ultraacid resistant quartz composite.

4. The rebuilt bases wereencapsulated with ARC 982,providing a very smooth finish as well as an acidresistant surface.

Note: Pump bases have been in operation since 1990,requiring no further maintenance.

10.1

ACID TILES


A P P E N D I X

OBSOLETE FLOORING SYSTEMS

ACID BRICK

ACID TILES


A P P E N D I X

ACID RESISTANT BRICK AND TILE

ADVANTAGES:■ Chemical and Abrasion Resistance■ Carbon Bricks for Hydrofluoric Acid

LIMITATIONS:■ Joints Crack From Thermal and Physical Stress

Mortar May Fail From Chemical AttackHigh Initial Cost and Down TimeCracks and Leaks Usually Go UndetectedA Membrane Would be Required for Positive Containment

TYPICALLY, 14 METERS (Yd)OF JOINTS PER m2 (Yd2) OF FLOOR, ALL POTENTIAL POINTS OF FAILURE (INGRESSION)

Acid Brick

Morter or Furan Leak Path


A P P E N D I X

OBSOLETE FLOORING SYSTEMS

FIBERGLASS POLYESTERS AND VINYL ESTERS

POSITIVE FEATURES■ Monolithic■ Some Have Excellent

Chemical Resistance

RESULTS■ Best utilized in temporary

operations, or possibly where constant repair of the system is not a problem

NEGATIVE FEATURES■ Frequent Disbondment

ShrinkagePoor AdhesionThermal Coefficient

■ Delamination Substrate Contamination and Degradation Go Unnoticed

■ Characterized by Rapid Undercutting Once Failure Occurs

■ Many are Hazardous

METHYLMETHACRYLATE MMA

POSITIVE FEATURES■ Good Weather Resistance■ Good Chemical Resistance■ Fast Cure

RESULTS■ Good for thin emergency repairs

on dry concrete

NEGATIVE FEATURES■ High Shrinkage■ Restricted to 3 mm (1/8 inch)

per Application■ Sensitive to Air or

Moisture During Cure■ Some are Explosive or Hazardous


A P P E N D I X

RESIN BASED FLOORING SYSTEMS

ADVANTAGES■ Monolithic, No Joints■ Easy To Install■ Wide Range Of Chemical Resistance

REASONS FOR FAILURE■ Chemical Attack

Improper Selection of Resin System■ Cracking and Disbondment From Concrete

Poor Surface PreparationDifferent Thermal Expansion Than ConcreteShrinkage StressesPoor Surface Wetting and Adhesion to Concrete

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