Specifying and applying
coatings for water and
wastewater treatment facilities
Consider exposure conditions and prepare surfaces carefully
to get maximum service life
BY PARKER M. YOUNG
THE SHERWIN WILLIAMS COMPANY
CLEVELAND, OHIO
city of 100,000 people re-
A quires 10 to 20 million gal-
lons of water daily. The re-
sulting wastewater pro-
duced daily contains 20 to 60 tons
of solids. In treatment facilities pro-
cessing these large quantities of wa-
ter and wastewater, concrete is ex-
posed to a harsh environment.
Coatings help protect the concrete
and prolong the life of the facility.
The coating system must protect
concrete from chemical attack by
acids. Sewer gas consists primarily
of hydrogen sulfide created by de-
composition of organic matter. The
gas combines with oxygen and wa-
ter condensed on concrete walls,
forming sulfuric acid that attacks
the concrete.
Sulfates of sodium, magnesium,
and ammonium also destroy con-
c re t e. These sulfates are found in
seawater, factory wastes, and some
groundwaters. Other chemical solu-
tions in wastewaters that attack
concrete include sugars, ferment-
ing liquids, ammonium chloride,
magnesium chloride, and ammoni-
um nitrate.
Moisture penetration may accel-
erate concrete deterioration. Freez-
ing of saturated concrete causes
spalling. Even in warm environ-
ments, moisture penetration may
contribute to rebar corrosion that
causes cracking and spalling. A
good protective coating system
keeps water from penetrating the
c o n c re t e, even during immersion
service. The coating also provides a
pleasing appearance for concrete
surfaces.
Coatings commonly used
for water and wastewater
treatment facilities
A number of coating systems
have good service histories and are
specifically engineered for the de-
mands of the water and wastewater
treatment industry. Coatings that
have proven particularly successful
after sustained use in the field in-
clude epoxies, coal tar epoxies, and
vinyls.
Two-component polyamide cur-
ed epoxies provide an extremely
hard, durable, tile-like finish for
concrete. Many are suitable for im-
mersion service. They are easy to
clean and are easily applied to prop-
erly filled and prepared concrete
s u rf a c e s. Because of their high
solids content, most epoxies comply
with strict air quality regulations
that limit the emission of volatile or-
ganic compounds to 31⁄2 pounds per
gallon. One disadvantage of epoxies,
howe ve r, is the tendency to chalk
when exposed to sunlight.
Coal tar epoxies are economical
and can achieve the required 16 to
20 mils dry film build with one or
two coats. They are commonly used
on concrete and steel to protect
against severe chemical attack and
abrasion. Coal tar epoxies develop
good adhesion to concrete and are
relatively easy to apply by brush,
roller, or airless spray. When specify-
ing coal tar epoxies, be aware that
there are some co-reactants
(amines, for example) that may
cause workers to break out in a rash.
Many manufacturers no longer use
such co-reactants.
Vinyl coatings have had an excel-
lent service history in immersion
service at water treatment plants.
They dry fast and aren’t temperature
dependent for curing. Vinyls,
though, have a lower volume of
solids that requires more coats to
achieve the required film thickness.
Some vinyls don’t comply with pre-
sent-day volatile organic com-
pounds requirements.
Exposure conditions
When specifying the coating sys-
tem, consider exposure conditions.
Types of exposure include:
■ Immersion service in tanks,
 troughs, aerators, filter beds, and
clarifiers
■ Moist atmospheric exposure in
tank exteriors and wetwalls
■ Moderate industrial service on
exterior concrete
■ Interior dry exposure on concrete
floors, walls, and masonry
Some specifiers use only immer-
sion-grade coatings for concrete be-
low the waterline and in the splash
zone above it. Typical coatings sys-
tems for immersion and splash-
zone service include high-build
epoxies applied in two or three
coats to dry film thickness of 12 to
18 mils, coal tar epoxies of 16- to 20-
mil thickness, and epoxy surfacers
with two coats of high-build epoxy.
Due to today’s higher solids and
higher viscosity materials, some
coatings don’t penetrate concrete
enough to achieve the best possible
adhesion. Adhesion can be im-
proved by first applying a sealer coat
of epoxy reduced to approximately
20% solids by volume. The sealer
penetrates pores and ties down any
residual dusting.
Moisture-saturated atmospheric

RECOMMENDED COATINGS FOR WASTE AND WATER TREATMENT PLANTS

Water Treatment Facilities Waste Treatment Plants
Surface Exposure Coating Surface Exposure Coating

Aerators Immersion Epoxy Aerators Immersion Coal tar epoxy

Basins Immersion Epoxy Nonimmersion Water-based acrylic
Building surfaces Weathering Water-based acrylic
Building surfaces Weathering Water-based acrylic
Interior-dry Latex
Interior-dry Latex Interior-wet Epoxy
Interior-wet Epoxy Chlorine room Interior Epoxy or chlorinat
ed rubber
Chlorination Nonimmersion-wet Epoxy
Clarifiers Immersion Coal tar epoxy
Clarifiers Immersion Epoxy
Nonimmersion Water-based acrylic
Nonimmersion-wet Epoxy Digesters Immersion Coal tar epoxy
Nonimmersion-dry Water-based acrylic Nonimmersion-dry Water-based acrylic
Clear wells Immersion Epoxy Filters Immersion Coal tar epoxy
Flocculators Immersion Coal tar epoxy
Nonimmersion-wet Epoxy
Gas holders Interior Coal tar epoxy
Coagulation basins Immersion Epoxy Exterior Water-based acrylic
Nonimmersion-wet Epoxy Greenhouse Nonimmersion-wet Epoxy
Nonimmersion-dry Water-based acrylic Weathering Water-based acrylic
Grit chambers Immersion Coal tar epoxy
Filter beds Immersion Epoxy
Nonimmersion-wet Epoxy
Nonimmersion-wet Epoxy
Lift stations Immersion Coal tar epoxy
Filter troughs Immersion Epoxy Nonimmersion-wet Epoxy
Flocculators Immersion Epoxy Parschall flumes Immersion Coal tar epoxy
Piping Immersion Epoxy Nonimmersion-wet Epoxy
Piping Immersion Coal tar epoxy
Nonimmersion-wet Epoxy
Nonimmersion-wet Epoxy
Nonimmersion-dry Water-based acrylic
Nonimmersion-dry Water-based acrylic
Pump stations Immersion Epoxy Primary tanks Immersion Coal tar epoxy
Nonimmersion-wet Epoxy Nonimmersion-wet Epoxy
Nonimmersion-dry Water-based acrylic Nonimmersion-dry Water-based acrylic
Pumping stations Immersion Coal tar epoxy
Reservoirs Immersion Epoxy
Nonimmersion-wet Epoxy
Sedimentation tanks Immersion Epoxy Nonimmersion-dry Water-based acrylic
Setting tanks Immersion Epoxy Secondary tanks Immersion Coal tar epoxy
Troughs Immersion Epoxy Sedimentation tanks Immersion Coal tar epoxy
Settling tanks Immersion Coal tar epoxy
Nonimmersion-wet Epoxy
Sludge beds Lining Coal tar epoxy
Wash water tanks,
Trickling filter tanks Immersion Coal tar epoxy
troughs Immersion Epoxy
Nonimmersion-wet Epoxy
Nonimmersion-wet Epoxy Nonimmersion-dry Water-based acrylic
Wet wells Immersion Epoxy Wet wells Immersion Coal tar epoxy
exposure occurs wherever wet sur-
faces are exposed to continuous
condensation in enclosed areas of
buildings or tank interiors. Usually,
immersion-grade coatings are spec-
ified for use in these areas too. They
may include an epoxy surfacer, 25 to
30 mils thick, and two coats of im-
mersion-grade epoxy, each 6 mils
thick. Once again, it’s best to use a
sealer coat before applying the coat-
ing system.
For moderate industrial exposure
in water and wastewater treatment
plants, use urethanes, water-based
acrylics, or silicone alkyds for exteri-
or exposure. For interior exposure
use epoxies, chlorinated rubber, or
water-based acrylics applied 7 to 9
mils thick.
Interior dry surfaces are coated
mainly for appearance and cleanli-
ness. Epoxy enamels are often used
on concrete floors, with latexes,
e p ox i e s, and other architec-
tural paints being used on walls and
ceilings.
The table shows recommended
coating systems for many different
water and wastewater treatment fa-
cility applications.
Effects of concrete properties
and construction methods on
coating adhesion
The performance of any coating
system is strongly influenced by
concrete surface condition. Surface
contaminants must be removed to
p re vent loss of bond between the
coating and the concrete. Su rf a c e
voids must be filled so that air bub-
bles don’t form beneath the coating
film. Here’s how to handle some of
the more common surface prepara-
tion problems:
■ Laitance—Laitance is a common
surface imperfection in slabs that
are placed with over-wet concrete
or are finished while there is still
bleedwater on the surface. The
laitance is a layer of weak materi-
al containing cement and aggre-
gate fines brought to the surface
by bleeding water. It is poorly
bonded to the underlying con-
c re t e, and any coating applied
to it eventually peels. Remove it
with light abrasive blasting
or acid etching before applying
the coating.
■ Efflorescence—Efflorescence is a
deposit of salts, usually white, on
a concrete surface. The salts are
water-soluble compounds that
originate in the concrete or in soil
or solutions in contact with the
concrete. They move to the sur-
face in solution form and remain
when the water evaporates. They
may be further altered chemical-
ly by contact with the air. Calcium
h yd roxide, for instance, forms
calcium carbonate when it is ex-
posed to carbon dioxide in the air.
If it’s caught soon enough, efflo-
rescence can be removed by
scrubbing with water. But if it has
already carbonated it will be in-
soluble in water. Muriatic acid
etching will remove the insoluble
residue.
■ Form oils and waxes— Form oils
and waxes aid in stripping forms
but may remain on the concrete
surface. The coating will then flow
away from the oil-saturated area
leaving it unprotected. Don’t use
form release agents if a coating
is to be applied later. To remove
form oils, scrub with an emul-
sifying agent and rinse with tap
water.
■ Air pockets (bugholes) and hon-
eycomb—These voids occur on
the surface or just beneath it. For
bugholes, the openings at the sur-
face may be small compared with
the holes’ actual sizes. Because of
this, it’s difficult to fill the holes
when coatings are applied. In-
stead, the coating traps air by
bridging over the hole. When the
temperature rises, the air expands
and forms a bubble in the coat-
ing. If the bubble breaks, it leaves
the concrete unprotected at that
point. Subsequent coats also
bridge over the hole and later
break. Light abrasive blasting is
the best surface treatment for
opening up bugholes. Holes larg-
er than 1⁄4 inch in diameter
should be filled by finishers. The
coating supplier may recommend
a product for filling holes smaller
than 1⁄4 inch in diameter. The
filler must be compatible with the
coating system.
■ Surface hardeners—Hardeners
are used on some floors to in-
crease surface hardness, increase
resistance to chemical attack, and
decrease permeability to liquids.
Because they produce a hard,
slick surface, howe ve r, these ma-
terials interfere with adhesion of
organic coatings. Avoid using
them on surfaces to be coated, es-
pecially for immersion service. If
a hardened surface must be coat-
ed, a light abrasive blasting pro-
duces the surface profile needed
for good adhesion.
Check with the coating supplier
before using hardeners, form re-
lease agents, curing compounds, or
other surface treatments. Make sure
they’re compatible with the coating
to be used.
Surface preparation methods
For best results from any coating
system, make sure all concrete sur-
faces are clean, dry, and well cured
before they’re coated. The surface
should have the texture of medium-
grit sandpaper and should be tight-
ly adherent, not powdery. There
a re n’t any all-inclusive national
standards for surface preparation or
its evaluation. Two sources of infor-
mation, howe ve r, are ACI Commit-
tee 503’s publications on barrier sys-
tems for concrete and ASTM
C 811-81 which covers surface
preparation.
Most coating manufacturers rec-
ommend coating concrete no earli-
er than 28 days after it’s been
placed. This period allows enough
curing for adequate strength gain
and enough time for adequate dry-
ing. If some of the moisture in the
concrete is not allowed to evapo-
rate, it can cause blistering and fail-
ure of the coating.
Use the ASTM D 4263 moisture
test to determine whether or not
concrete is sufficiently dry to coat it.
Cover a 1x2-foot area of concrete
with a clear 4-mil plastic sheet
sealed at the edges with duct tape.
Remove the sheet after 24 to 48
hours. If there’s condensation on the
side of the sheet toward the con-
crete or if the covered area is darker
than the exposed area, the concrete
is too wet to coat. Moisture meters
a re n’t a reliable alternative for this
test. Results may be unreliable be-
cause the meters don’t always mea-
sure moisture that is migrating to-
ward the surface.
Blast and fill hollow areas, bug-
holes, honeycombs, and voids.
Grind to round off all fins, form
m a rk s, and protrusions or rough
edges. This provides a smooth, con-
tinuous surface with the correct tex-
ture for coating.
Remove all grease, dirt, paint, oil,
tar, glaze, laitance, efflorescence,
loose mortar, and cement. Two of
the most common methods for do -
ing this are blast cleaning and acid
etching. Be aware, though, that
chlorides in muriatic and hy-
d ro c h l o ric acid attack and may
cause stress corrosion cracking of
Type 304 stainless steel piping.
Blast cleaning includes dry abra-
sive blasting, water blasting with
abrasives, and vacuum blasting with
a b ra s i ve s. Use suitable size abra-
sives and oil-free air to remove con-
taminants and open bugholes. Vac-
uum or blow down and remove dust
and loose particles from the surface.
Vertical and overhead surfaces
are difficult to etch, but acid etch-
ing is feasible for previously uncoat-
ed horizontal concrete surfaces. Al-
low the acid to remain on the
surface until frothing action stops.
Drain, thoroughly rinse with large
amounts of clean water, and scrub
with a stiff brush to remove scum. It
may be necessary to repeat this
process several times if the texture
of medium-grade sandpaper isn’t
achieved on the first etch. Bring the
pH of the surface to neutral with a
3% solution of trisodium phos-
phate, then flush with tap water. Be-
fore coating, allow the surface to dry
and check it for moisture using the
ASTM D 4263 test described earlier.
Coating application,
inspection, and maintenance
Mandatory hold points during
surface preparation and coating ap-
plication can help ensure a satisfac-
tory coating job. Inspect the work
after surface preparation and after
each coat has been applied. Docu-
ment the inspection results and re-
tain them for reference. Record re-
sults of moisture tests on the
c o n c re t e. Monitor coating thick-
ness, both wet and dry. Verify that
correct mixing ratios are being used
for two-component systems. Also
record ambient conditions and sur-
face and material temperatures dur-
ing application and curing.
Most co-reacted epoxies require
air, surface, and material tempera-
ture to be at least 55° F for 24 hours
before coating application. Also
maintain this minimum tempera-
ture during application and curing
or drying of the coating.
The MEK rub test is commonly
used to determine whether or not
an epoxy film has cured sufficiently.
Rub the surface 30 times with a rag
soaked in methyl ethyl ketone
(MEK). Then inspect the surface for
any evidence of softening or being
dissolved by the solvent.
Follow a regularly scheduled pro-
gram of inspection, touch-up, and
maintenance to ensure that the sys-
tem reaches its design service lift.
Inspect at 6-month intervals for
server exposure installations and at
12- to 18-month intervals for mod-
erate exposures.
Repairs are needed when up to
10% of the coating area has been
chemically or physically damaged.
For coatings in atmospheric service,
clean the damaged area with power
tools, spot prime it, and finish coat it
with the original coating system. For
failed coatings in immersion
s e rv i c e, spot blast back at least 1
inch into sound film. Then feather
the edges and recoat with the origi-
nal system. When the coating sys-
tem has deteriorated to about one-
third of the total area, it may be
more economical to consider a
complete recoat with the original
coating system.
PUBLICATION #C900384
Copyright © 1990, The Aberdeen Group
All rights reserved