Acid brick is an industry standard and a long lasting floor system that protects against chemically aggressive environments. These systems utilize protective membranes in conjunction with chemically resistant mortars/setting beds followed by brick to protect against thermal shock.
A recent application of this type of system was installed in a lead acid battery facility, protecting the process floor and trenches from sulfuric acid exposure. We used the Carbo-Alkor mortar along with our Atlastic 40 membrane to provide a floor system that will protect for years to come.
In the last couple years we have seen a resurgence in the Battery Industry. There have even been some large greenfield projects in the midwest and northeast we were able to take advantage of. While new plants may not be the norm, the maintenance and upkeep of current facilities are something that Atlas thrives on. It does not matter if the company is manufacturing or recycling in the battery process, the common theme is that they are spending money. In fact, the global lead acid battery market is on track to reach almost 60 billion by 2020 due in large part to the domestic key players we currently work with.
The Atlas product line lends itself to almost every area of a battery plant. Whether on a formation room floor using our brick and mortar system, in a trench run/sump using Anchor-Lok, or even at a hand washing/laundry station using our polymer concrete… there is a need for our products in these facilities.
A recent example of our products in action was in the Southeast. This facility had a 60-foot trench run that needed to be repaired and replaced. It was in terrible shape and like most plants could not afford to be shut down for any extended period of time. We were given a week to have the trench run cleared out, placed and welded. This was a task that our engineering, welding and fabrication team(s) handled flawlessly. This project should lend itself to more opportunities within this company’s locations across the country.
Atlas’s expertise and experience in this particular market segment is second to none. Use it to your advantage.
Trench with concrete issues. In this facility, acid was attacking the concrete substrate from behind the existing liner
Concrete was repaired and Anchor-Lok was set in the trench
Engineer prints allowed Atlas to manufacture the trench run to a custom fit
Anchor-Lok is grouted into place
A coating system bridges the gap between the existing concrete and Anchor-Lok's fabric facing. The fabric allows the coating to bond to the Polypropylene trench
A final floor system is applied over the coating, giving a seamless transition between the floor and the trench
In 1988, Atlas Minerals was asked to propose a solution for a failed acid-resistant brick lining for the absorber cell of the scrubber system at a major coal fired power plant. Later that year, the lining was complete and the Anchor-Lok (called Bekaplast in the attached article) is still performing to this day.
Whether it be for Power Generation, Wastewater Treatment or Process Industries, Atlas Minerals’ Anchor-Lok thermoplastic lining system can protect your concrete from the most aggressive chemicals and environments that you encounter. Since the Anchor-Lok lining is cast into the wall instead of applied to it, all of the typical pitfalls associated with conventional liquid applied linings are eliminated.
If you can form it in concrete, you can line it with Anchor-Lok.
Anchor-Lok for Power Generation
One of the recurring facility maintenance challenges that will test any waterproofing system is the gutter lining system. Industry standard practice over the years has been to line them with a single-ply membrane. In general, this approach will last 10-years, perhaps a little more, before we begin to see deterioration of the seams or of the membrane itself. Often times these are complex configurations (requiring numerous seams) that hold water and do not readily drain. Frequently adding to the dilemma is the presence of multiple substrates that need to be incorporated into the waterproofing system to facilitate the removal of water from the roof without creating opportunities for it to enter the building.
An ideal lining system would:
1) Contain no seams
2) Conform to complex configurations (no tenting beneath the membrane)
3) Tolerate ponding water without exception
4) Be fully adhered so water cannot migrate under the membrane
5) Be capable of bridging gaps and joints between dissimilar substrates
6) Be fully reinforced to accommodate the movement between dissimilar
7) Be applied by trained installers and backed by a reputable company
Many times these linings will need to be offered in colors that match architectural features that, for historical or even personal preference, need to be maintained. Sikalastic RoofPro is offered in 5 standard colors.
During the course of normal day-to-day operations or just as a function of the time of year, many areas of a facility never reach temperatures that are conducive to performing resinous flooring installations. Seldom does the owner ever have the luxury of allowing substrate temperatures to rise just so this type of work can be done.
Atlas Minerals understands the dilemma and has formulated several materials and systems that are designed to permit maintenance work to be performed with minimal production downtime due to cold temperatures.
Attached is the Atlas Low Temperature products listing. If you’re not sure which is right for you, give us a call!
ATLAS LOW TEMPERATURE SYSTEMS
As many in the industry can will agree with, complex details on roofs are difficult items to contend with and often times expensive to waterproof. This is especially the case if seams break and membranes fail within warranty periods. Perhaps one of the most commonly failing details on commercial roofs are skylights, and luckily, there is an alternative to full replacement when skylight details leak. Within the Roofpro line of Liquid Applied Membranes, Sika offers Clearglaze: a clear coating solution to leaky skylights that costs a fraction of full replacement.
How it works: The Clearglaze system creates a monolithic, seamless, and light transmittable membrane in a few easy steps.
- Prime the glazing details with the appropriate membrane primer
- Use reinforcement and pigmented resin to “picture frame” in the glazing details to the glass
- Cover the main body of the skylight with Clearglaze at 40 mils.
As with the pigmented Roofpro material, execution is dependent on the contractors ability to get trained. While these are the basic steps to covering the skylight, training sessions will highlight the intricate details of perfecting this process. As skylights continue to be implemented in architectural design, the notion of leaking seams and details are unavoidable. However, this approach offers some major benefits:
- Occupied space below the skylight is not disturbed. This proves valuable in retail and education settings
- Carrying buckets of liquid up to a roof eliminates some rigging costs associated with tear out and replacement
- A seamless and monolithic membrane can be carried onto the main body of the roof
- A seamless and monolithic membrane will allow for ZERO leak points
For some, these benefits far exceed the the desire to replace or repair the same structure in a few years. While the final product may not be 100% optically clear, the 98% of the light transmittance remains with the Clearglaze system. View a few images below, and consider full encapsulation of a leaky skylight as opposed to a costly replacement!
When it comes to food, often times consumers consider the convenience, quality and nutritional factors associated with the product. However, consumers are often unaware of the controls and requirements that must be put into place in order to safely process food. In the food and dairy industries, companies must be aware of the sanitizing agents and overall conditions within the facility so as not to invite unwanted issues.
One of the main issues in the industry is the abuse that floors receive. In dairy and food processing facilities, brick and tile floors are subject to intense thermal shock, harsh sanitizing agents and mechanical abuse. Some general operating conditions found in these facilities are:
- Floors are always wet – subjected to frequent spills
- Ambient air temperatures are cool, usually between 40oF (4oC) and 50oF (10oC)
- Sanitization is a high priority to reduce potential of bacterial contamination
- Requires an aesthetic appearance and easy to clean / sanitize floor system
- Subjected to frequent tractor / trailer traffic, impact from hose couplings, lactic acid, frequent wash downs.
Given these intense conditions, reliable floor systems must be able to:
- Hold up to a wide range of sanitizing agents
- Prevent bacterial contamination
- Contain grouts that will withhold hot water thermal shock or low temperatures
- Have slip resistance
Atlas Minerals and Chemicals recognizes the industry standards for food processing, dairy and other beverage facilities. With a ride range of brick/tile, coating, lining and setting materials, we can address and solve problems in this industry. From truck/loading stations, Clean In Place (CIP) rooms, cooler rooms, or production and filling rooms, Atlas Minerals has the materials to withstand high demand environments.
For some basic information on potential floor solutions from Vitrified tile to coating and lining solutions, click here. If you are in the North or South Carolina territory, do not hesitate to reach out and we will be happy to help.
Today’s water and wastewater treatment facilities demand the very best coatings to protect their assets from harsh corrosive atmospheres. Induron Protective Coatings have developed high performance coating solutions for the numerous exposures encountered in these treatment plants. Induron’s ceramic epoxies have been protecting water, wastewater and sewer structures for over 30 years.
Induron’s line of ceramic epoxies offers:
- Absolute Minimal Undercutting: Healing pinholes and spot corrosion with A-rated cathodic disbondment
- High Film Build: Minimizing risk of holidays and improved edge protection
- Low-Permeability: Keeping corrosive liquids away from a substrate
- Non-Ablative Surface: Inhibiting microbiological contamination and preventing acidithiobacillus growth.
Whether it is in the waste water treatment field, or potable water storage, Induron’s ceramic epoxies provide a solution. See the Permasafe 100 data sheet for wastewater facilities, or the Permaclean 100 data sheet for potable water storage.
While there are several variables that enter into the successful completion of a construction project, perhaps the most important factor is time. Whether it is a college/university doing a summer renovation on student housing, or an office building with plans to rent out space, timelines are important to all parties involved.
Typically, tear offs will require that the building be dried in at the end of each working day. Industry practice has been to tear off the first half of the day, clean up, and begin torching down or adhering a base sheet to achieve temporary waterproofing. The Tritoflex system allows the contractor to achieve temporary waterproofing at a much more rapid rate than with conventional sheet good materials. The result is a 40 mil, completely seamless, instantly waterproof membrane. The Tritoflex liquid is water based, zero VOC and with nearly 2000% elongation, can accommodate movement of the substrate.
For more information see our Triton page at Triton Waterproofing
New for 2015 are the latest entries into the Sikalastic RoofPro family of products, Sikalastic 641 and Sikalastic 644. Sikalastic 641 and Sikalastic 644 are the low odor alternatives to the Sikalastic 621 (Decothane) and Sikalastic 624 AR (Balcons) moisture triggered aliphatic urethanes. Application characteristics employ the same, easy to use, techniques that installers are accustomed to with the other seamless, reinforced Sikalastic RoofPro materials, without the same odor.
First introduced in the 1980’s, Sikalastic RoofPro remains in a class of it’s own and unmatched in field experience by it’s liquid applied membrane competitors. Renewable warranty durations of 10-25 years (labor & material) are available over a variety of deck substrates as well as to virtually all existing roof membranes.
Click below to view the Sikalastic RoofPro Brochure