600 Coating Concrete

Abstract
This section focuses on basic projects for coating concrete. Topics covered include:
the most suitable coatings and coating systems, how to assess and repair the
concrete surface, and issues peculiar to coating concrete.
Before preparing the surface, it may be necessary to repair common, non-structural
damage to the concrete such as holes and cracks. For structural repair of concrete,
which is beyond the scope of this manual, contact the Company's civil and struc-
tural engineers.
When selecting a concrete coating, it is important to know its intended exposure,
such as environment, temperature, and immersion. The selection guides and data
sheets for coating concrete in mild environments are available in the Quick Refer-
ence Guide. For critical projects, consult one of the Company's coating specialists
(also listed in the Quick Reference Guide).
From the standpoint of application, there is no one standard technique because of
the complexity of this surface. While general information is offered in this section,
specific assistance is available both from manufacturers and the Company's coating
specialists.

Contents Page
610 Coating Concrete in General 600-3
611 Existing Structures or New Construction
612 Engineering Assistance
613 Reasons for Coating Concrete
620 Descriptions of Coatings for Concrete 600-4
621 Coatings
622 Coating Systems
630 Selection 600-9
631 Defining Conditions
640 Assessing and Repairing Concrete 600-10
641 Assessing the Surface

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642 Repairing Non-structural Damage

650 Surface Preparation 600-20
651 Pre-application Requirements
652 Precleaning
653 Mechanical and Chemical Cleaning
660 Application 600-22
661 Recommended Process
662 Reviewing an Application Procedure
670 Inspection 600-23
680 References 600-24

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610 Coating Concrete in General

There are many factors to consider at the outset of a concrete coating project. Some
factors are:
• Whether or not the structure is existing as that affects the level of surface prepa-
ration required
• The level of engineering assistance necessary for the project
• The reasons for coating concrete which fall basically into two categories: prac-
tical maintenance and safety regulations

611 Existing Structures or New Construction

Because of the extra surface preparation required, an existing structure is usually
more difficult to coat than a new structure. Existing structures may require:
• Removal and repair of corroded or damaged concrete
• Repair of corroded reinforcing bars
• Repair of existing cracks
• Removal of two to three inches of contaminated concrete
These repairs may involve rebuilding the structure with either fresh concrete or an
epoxy polymer material.
During initial design, review all potential problems with coating or lining a new
structure. If new construction is designed to accept a coating or lining, the coating
will cost less and will be less likely to fail prematurely.

612 Engineering Assistance

Coating or lining concrete has so many variables that this section cannot cover all of
the possible situations. This section represents an overview of the information
required to coat or line concrete.
Before coating or lining a concrete structure, evaluate the difficulty of the project
and, for critical projects, contact the Company's coating specialists listed in the
Quick Reference Guide.
Example: One criterion for a critical project is that a premature failure could seri-
ously affect the Company.

613 Reasons for Coating Concrete

Practical maintenance, safety, and complying with regulations are the main reasons
for coating concrete.

Practical Maintenance and Safety

The following discussion details reasons for coating concrete on the basis of prac-
tical maintenance and safety.

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Protection from the environment. One of the most important factors in selecting a
coating system is its environment: exposure to temperature, physical abuse, and
immersion service.
Concrete may require protection from its environment in API separators, sulfur pits,
pump bases, floors, or other primary containment.
Protection from wear. One of the main uses of coatings for concrete is to protect
floors from wear. There are coating systems designed for foot, light vehicular, and
heavy equipment traffic.
Maintenance. Because concrete is a porous material, it retains dirt and stains easily.
Coating concrete can reduce significantly the cost of routine cleaning.
Safety. Non-slip or skid resistant coatings are available for traffic safety on
concrete.

Regulations
In addition to practical maintenance, existing regulations require owners to protect
concrete with coatings and linings. A discussion of some regulations follows.
Under the Resource Conservation and Recovery Act (RCRA), owners must install
secondary containment, such as impoundment basins, for aboveground tanks that
store hazardous wastes. While concrete is one of the most cost-effective materials
for this service, RCRA does not consider concrete a material suitable for containing
hazardous wastes unless it is coated or lined.
Example: An impoundment basin is one form of secondary containment.
Under the Oil Pollution Act of 1990, Congress mandated that the Environmental
Protection Agency (EPA) study the need for regulating aboveground petroleum
storage tanks. This impending regulation could result in the Company having to line
or provide secondary containment for all petroleum storage tanks.
It is also possible that State and local environmental agencies might create and
enforce equal or more stringent regulations for secondary containment.
Regardless of current regulations, consider coating concrete wherever it is neces-
sary to contain or exclude fluid.

620 Descriptions of Coatings for Concrete

While there are many resins available for coating concrete, none are perfect. Selec-
tion depends on the coating's environment and exposure to corrosive media, temper-
ature, and physical abuse. When several resins are equivalent, then cost and ease of
application become the selection criteria.
Listed in alphabetical order, the five major resins for coating concrete structures are:
epoxy, isophthalic polyester, novolac epoxy, polyurethane, and vinyl ester. General
information about some of these resins is also available in Section 100 of this
manual.

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The four main systems for coating concrete are as follows: non-reinforced thin film,
flake-reinforced, glass-flake laminate, and elastomeric polyurethane.
As most coating systems for steel are equally suitable for concrete, see Section 100
of this manual for general information about non-reinforced, thin-film, and glass-
flake-reinforced coatings.

621 Coatings
Epoxy
Epoxy resins are the most common, thin-film coatings for concrete.
Advantages:
• Very good resistance to bases and many solvents
• Good adhesion to concrete and are easy to apply
Disadvantages:
• Poor resistance to acid unless modified by a phenolic

Isophthalic Polyester
There are two major classes of polyester resins, but the Company uses only isoph-
thalic which is the main resin in laminate-reinforced systems.
Advantages:
• Corrosion protection
• Least expensive resin
Disadvantages:
• Poorer resistance to chemicals than other resins

Epoxy Novolacs
Novolacs are second generation epoxies with greater cross-linking density.
Advantages:
• Greater resistance to chemical attack and high temperatures than all other
epoxies
Disadvantages:
• More expensive and less flexible when compared to standard epoxies

Polyurethane
There are literally thousands of polyurethane formulations from hard roller-skate
wheels to elastomeric materials with the elasticity of rubber bands.

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Advantages:
Through its wide variety of formulations, polyurethane can have many different
properties.
• Chemical, abrasion, and impact resistant
• Tensile strength
• Elasticity
Note Because increases in one property mean decreases in another, many elasto-
meric polyurethanes are not as chemically resistant as the more rigid polyurethanes.
Disadvantages:
• Some elastomeric formulations are not very resistant to chemicals.

Vinyl Ester
A reaction product between polyesters and epoxies, vinyl ester shares many of the
attributes of polyesters.
Advantages:
• Resistant to acid
• Resistant to solvent attack
• Resistant to high temperatures
Disadvantages:
• More costly than an isophthalic polyester or normal epoxy

622 Coating Systems

Thin Film
Thin film is only 10 to 20 mils thick and contains no flakes, fibers, or laminates for
reinforcement. Usually, this coating has some inert fillers such as silica or carbon to
reduce shrinkage during cure and to improve resistance to abrasion. A thin-film
system needs two or three coats: a primer/sealer and one or two high-build topcoats.
Recommended dry film thickness (DFT) is 15 to 20 mils, with thicker DFT for more
severe services.
Advantages:
• Low cost due to use of the least amount of material, no expensive hand work
required, and easiest to apply
Disadvantages:
• Thinness of film which leads to lack of resistance to abrasion, severe chemical
attack, and physical abuse
• Unreinforced film which means it will not bridge existing cracks

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Uses:
• Mild service conditions
• Splash or spillage environments
• Temporary service

Flake-reinforced
The flake-reinforced coating system is the most common system for concrete.
Flake-reinforced coatings come in both spray- or trowel-applied formulae. Spray is
generally applied in two 15 to 20 mil (DFT) coats for a total of 30 to 40 mils (DFT).
Trowel applied, with a larger reinforcing flake size, is generally applied in two 30 to
40 (mil) coats for a total of 60 to 80 mils (DFT).
Advantages:
• Excellent properties for most environments
• Better than thin film at resisting chemical attack (parallel flakes reduce the
coating's permeability) and physical abuse by abrasion
• Cost less than laminate systems
Disadvantages:
• Rolling is necessary for each layer of either formula so that the flakes lie
parallel to the surface.
☞ Caution Although some manufacturers claim their spray formulae are self
leveling and do not require rolling, always roll this coating to improve its proper-
ties.
Flake-reinforced Sprays. The flake-reinforced spray is applied much like a thin-
film system.
Advantages:
• Twice the thickness of thin films; covers a more uneven surface than thin film
Disadvantages:
• Because they require rolling and extra material, these sprays are marginally
more expensive than thin films but not as costly as the trowel-applied formula.
Trowel-applied Flake-reinforced Coatings.
Advantages:
• More resistant to chemical attack, abrasion, and physical abuse than either the
flake-reinforced spray or thin-film systems
Disadvantages:
• Application considerably more difficult and time consuming than either the
flake-reinforced spray or the thin-film systems; hand smoothing and then
rolling is necessary to orient the glass flakes

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Glass-flake Laminate
Laminate-reinforced systems are applied by hand in alternating layers of resin and
glass mat. These coating systems:
• Generally have three layers of resin and two layers of fiberglass mat
• Have a total thickness is 80 to 125 mils
• May require a special surfacing veil and final resin topcoat for some of the
more aggressive services; chemical glass or polyester are the most common
surfacing veils.
After inspecting the completed laminate system, apply a final 10 mil (DFT) resin
coat without which the surface would remain tacky and lack optimum chemical
resistance.
With epoxy resins, this coat gives additional protection from chemical attack and is
called a gel coat. With polyester and vinyl ester resins, the final coat is a 90/10
mixture of resin and wax.
Advantages:
• For severe applications
• Adds structural strength
• Best chemical, wear, and impact resistance
Disadvantages:
• Hand-applied, laminate-reinforced coatings are by far the most expensive

Elastomeric Urethanes
Elastomeric urethanes, developed as internal coatings for tanks, are thicker than
most non-reinforced coatings (30 to 60 mils or more). Applied in one coat, these
tough, rubbery coatings are suitable for certain special applications but are not
among the standard systems because the Company has limited experience with them.
There are two types of elastomeric systems: textile-reinforced and non-reinforced,
both of which can be applied at 40 mils (or greater) DFT.
Advantages:
• Depending on their formulation, elastomeric systems can have very good resis-
tance to impact, abrasion, and wear.
• Because they are elastomeric, manufacturers also claim they can bridge cracks.
☞ Caution While the claim about bridging cracks may be true to some extent, be
certain to design and specify proper repair of all cracks and joints before coating.

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Disadvantages:
• All elastomeric systems have a modified polyurethane resin which makes the
system more expensive than some flake-reinforced and thin-film systems.
• Polyurethanes are very moisture sensitive during application.

630 Selection
For definitions of environment, physical abuse, and exposure, see Figures 600-1
through 600-5.
See the Quick Reference Guide for selecting concrete coatings in mild
environments.
For coating concrete in moderate-to-aggressive conditions, contact the Company's
coating specialists listed in the Quick Reference Guide.

Fig. 600-1 Definitions of Environment, Physical Abuse, and Exposure for Concrete Coatings
Description Environment Physical Abuse Exposure
Mild < 140°F, mild acids, No coating loss due to abrasion; N/A
bases, solvents possible light foot traffic. No physical
impact on coating.
Moderate < 140°F, strong Moderate coating loss due to abrasion, N/A
acids, bases, light equipment wear. Possibility of
solvents impact on coating.
Aggressive > 140°F, strong Severe coating loss due to abrasion, N/A
acids, bases, heavy equipment wear. Definite poten-
solvents tial for impact on coating.
Continuous N/A N/A Exposed to the corrosive medium
for longer than 24 hours.
Intermittent N/A N/A Exposed to the corrosive medium
for less than 24 hours—usually
splash or spillage that is cleaned
up within 24 hours

631 Defining Conditions

Before calling the Company's coating specialists, know the following information
about the conditions anticipated for the concrete coating. Refer to Figure 600-1 for
definitions, and also Figures 600-2 through 600-5.
Environment. To what temperature and corrosive media is the coating exposed:
aggressive, moderate, mild?
Physical Abuse. To what extent is the coating exposed to abrasion such as from
foot traffic, light cleaning, automobile traffic: aggressive, moderate, mild?
Exposure. Is the coating exposed to chemicals continuously or intermittently?

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Fig. 600-2 Coating Recommendations for Continuous Immersion

640 Assessing and Repairing Concrete

All concrete must be clean, dry, and in sound condition to receive a coating or lining
system. While this surface may be easy to achieve with new construction, it may be
expensive for existing structures.
Before concrete can be prepared to accept a coating, ensure that the substrate:
• Is properly cured and dry. The coatings applicator should tape a black plastic
sheet over the substrate and check for moisture after 24 hours (ASTM D-4263).
• Has a minimum compressive strength of 3,000 psi
• Has a surface strength of at least 200 psi. To measure the surface strength, the
inspector or Company's representative should attach a metal piece to the
concrete with adhesive and measure the force needed to remove it (ASTM
Standard Method M-4541).
• Has a uniform surface free of excessive defects and laitance. To finish new
concrete, the coatings applicator should smooth once over the surface with a
wood float and then use a steel trowel.
Note Laitance is the film caused when a water-rich cement rises to the surface
during finishing. Remove this 5- to 50-mil-thick film before applying any coating.

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Fig. 600-3 Coating Recommendations for Continuous Immersion Service

Recommendation #1: Use a laminate reinforced with the coating manufacturer to ensure it is resis-
system to resist physical abuse and chemical tant to the corrosive media. It will probably be an
attack. The resin selection should be reviewed with epoxy, novalac epoxy, or vinyl ester resin.
the coating manufacturer to ensure it is resistant to
Obtain the assistance of a specialist in coating
the corrosive media. It will probably be an epoxy
concrete. By evaluating specifics of your project,
novalac or vinyl ester resin.
he may be able to recommend a flake reinforced
Because of the severe service obtain the assistance system instead. Depending on the size of your
of a specialist knowledgeable in repairing and project this could result in considerable cost
coating concrete. See the Quick Reference Guide savings.
for a list of recommended specialists.
Recommendation #5: Use a flake reinforced
Recommendation #2: Use a flake reinforced system to resist the chemical attack. The resin
system to resist chemical attack and the reduced selection should be reviewed with the coating
physical abuse. A laminate system would work manufacturer to ensure it is resistant to the corro-
here but at twice the cost. The resin selection sive media. It will probably be an epoxy, epoxy
should be reviewed with the coating manufacturer novalac, or vinyl ester resin.
to ensure it is resistant to the corrosive media. It
will probably be a novalac epoxy or vinyl ester Recommendation #6: Use a flake reinforced
resin. system to resist the chemical attack. The resin
selection should be reviewed with the coating
Because of the aggressive corrosive media, obtain manufacturer to ensure it is resistant to the corro-
the assistance of a specialist knowledgeable in sive media. It will probably be an epoxy, epoxy
repairing and coating concrete. See the Quick novalac, or vinyl ester resin.
Reference Guide for a list of recommended special-
ists. Recommendation #7: Use a laminate reinforced or
a textile reinforced urethane system to resist the
Recommendation #3: Use a flake reinforced physical abuse. The resin selection should be
system to resist chemical attack. Even with the reviewed with the coating manufacturer to ensure it
mild physical abuse do not use a thin film system. is resistant to the corrosive media. It will probably be
The thicker flake reinforced system is required to a polyester, epoxy, or modified urethane resin.
resist the severe environment. The resin selection
should be reviewed with the coating manufacturer Recommendation #8: Use a flake reinforced or a
to ensure it is resistant to the corrosive media. It textile reinforced urethane system to resist the phys-
will probably be a novalac epoxy or vinyl ester ical abuse. The resin selection should be reviewed
resin. with the coating manufacturer to ensure it is resis-
tant to the corrosive media. It will probably be a
Because of the aggressive corrosive media, obtain polyester, epoxy, or modified urethane resin.
the assistance of a specialist knowledgeable in
repairing and coating concrete. See the Quick Recommendation #9: Use a flake reinforced or a
Reference Guide for a list of recommended special- textile reinforced urethane system. Because this is
ists. immersion service, use a reinforced system. The
resin selection should be reviewed with the coating
Recommendation #4: Use a laminate reinforced manufacturer to ensure it is resistant to the corro-
system to resist physical abuse. A flake reinforced sive media. It will probably be a polyester, epoxy
system would be adequate to resist the chemical or modified urethane resin.
attack. The resin selection should be reviewed

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Fig. 600-4 Coating Recommendations for Intermittent Immersion/Splash/Spillage

641 Assessing the Surface

New Structures
During the initial design of a new structure, investigate potential problems involving
coatings or linings to reduce costs and premature failures.
If laid properly, new concrete requires only cleaning of surface dirt, oil, laitance,
etc., before abrading. There may, however, be other items to consider such as vibra-
tion, agents and slivers, and curing.
Vibration. Vibration consolidates the concrete but can also cause water and air
bubbles to move out to the face of the form, resulting in tiny voids or holes in the
concrete surface. Before coating or lining concrete, fill all holes, including those
opened during surface preparation.
Agents and Slivers. Many forms are built with commercially available plywood or
wood planks. When removed, these forms may leave other materials in the concrete
such as release agents that facilitate the removing forms, or large slivers of wood.
Remove these materials, then repair and smooth the area before coating it.
Curing. Unless the concrete cures properly, it may crack; if so, repair all cracks
before coating or lining.

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Fig. 600-5 Coating Recommendations for Intermittent Immersion Service

Recommendation #10: Use a laminate reinforced
system to resist the physical abuse and chemical
attack. The resin selection should be reviewed with
the coating manufacturer to ensure it is resistant to
the corrosive media. It will probably be an epoxy,
novalac epoxy, or vinyl ester resin.
Depending on the type of physical abuse, a flake
reinforced system could be used. This should be
confirmed with someone experienced with coating
concrete.
Recommendation #11: Use a flake reinforced
system to resist the chemical attack and the
reduced physical abuse. The resin selection should
be reviewed with the coating manufacturer to
ensure it is resistant to the corrosive media. It will
probably be an epoxy, novalac epoxy, or vinyl ester
resin.
Recommendation #12: Use a flake reinforced or
thin film system to resist the chemical attack. The
selection of reinforced or thin film will depend on
the amount of mild physical abuse. The resin selec-
tion should be reviewed with the coating manufac-
turer to ensure it is resistant to the corrosive
media. It will probably be an epoxy, novalac epoxy,
or vinyl ester resin.
Recommendation #13: Use a laminate reinforced it is resistant to the corrosive media. It will prob-
system to resist the physical abuse and chemical
attack. The resin selection should be reviewed with resin.
the coating manufacturer to ensure it is resistant to
the corrosive media. It will probably be an epoxy,
novalac epoxy, or vinyl ester resin.
Depending on the type of physical abuse, a flake
reinforced system could be used. This should be
confirmed with someone experienced with coating Recommendation #18: Use a thin film or elasto-
concrete.
Recommendation #14: Use a flake reinforced or
thin film system to resist the chemical attack. The
selection of reinforced or thin film will depend on
the amount of moderate physical abuse. The resin
selection should be reviewed with the coating
manufacturer to ensure it is resistant to the corro-
sive media. It will probably be an epoxy, novalac
epoxy, or vinyl ester resin.
Recommendation #15: Use a thin film system to
resist the chemical attack. The resin selection
should be reviewed with the coating manufacturer
to ensure it is resistant to the corrosive media. It
will probably be an epoxy, novalac epoxy, or vinyl
ester resin.
Recommendation #16: Use a laminate reinforced
or a textile reinforced urethane system to resist the
physical abuse. The resin selection should be
reviewed with the coating manufacturer to ensure
it is resistant to the corrosive media. It will prob-
ably be a polyester, epoxy, or modified urethane
resin.
Depending on the type of physical abuse, a flake
reinforced system could be used. This should be
confirmed with someone experienced with coating
concrete.
Recommendation #17: Use a flake reinforced or
elastomeric urethane system to resist the moderate
physical abuse. The resin selection should be
reviewed with the coating manufacturer to ensure
ably be a polyester, epoxy, or modified urethane
Depending on the type of physical abuse, a thin
film system could be used. This should be
confirmed with someone experienced with coating
concrete.
meric urethane system. The resin selection should
be reviewed with the coating manufacturer to
ensure it is resistant to the corrosive media. It will
probably be an epoxy or modified urethane resin.

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Existing Structures
Attacked by chemicals, contaminated by hydrocarbons, and damaged by mechan-
ical means, existing concrete may require extensive repairs and surface preparation.
A careful inspection should determine whether or not the existing concrete is struc-
turally sound.
Corrosion. Depending on the amount of corrosion in the steel reinforcement, the
concrete will require the following:
• Corroded - Coating or cathodic protection in aggressive environments
• Severely corroded - Replacement of steel reinforcing and the affected concrete
or epoxy-polymer material
Contamination. Depending on the level of contamination, concrete that has been
exposed to oils or other impurities may require high-pressure detergent-and-water
cleaning. It also may require replacing as many inches of concrete as necessary to
remove the contaminants.

642 Repairing Non-structural Damage

There are several common kinds of non-structural damage to concrete, such as
cracks, holes, expansion joints, and drain and pipe penetrations.

Cracks
Among the choices for repairing concrete based on the size and activity (still
moving) are the following:
• Filling them with a sealer
• Making them into expansion joints
• Filling them by pressure injection
Begin with the basic procedures for filling concrete cracks, regardless of size.
Basic Procedure for All Cracks. To repair all cracks, begin by:
1. Blowing any standing water out of the crack
2. Removing oils or chemicals in the crack
☞ Caution Do not inject solvents into cracks to remove oils or chemicals because
this process actually dilutes the contaminants and carries them further into the
concrete surface. Instead use an injection grout that will solubilize the oils and
water, bond to the concrete, and cure with suitable properties for the intended
purpose.
Continue the repair—depending on the size of the crack—by following the steps
either for small or for large cracks, below.

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Additional Steps for Small Cracks. To repair small cracks, there are two
alternatives.
Alternative One: Filling with Sealer
1. Grind the crack into a V shape with an opening that is a minimum of ½-inch
wide at the surface of the concrete.
2. Pour or trowel the sealing grout into the crack.
3. Scrape off excess grout.
Alternative Two: Creating Expansion Joints.
Convert small cracks into expansion joints, which allow concrete to expand and
contract with changes in temperature or movement of the substrate. See Figure
600-6, Detail “C”; this figure also covers corrosion control of floor-to-wall expan-
sion joints and floor-to-wall control joints.
As they are highly susceptible to premature failures, design expansion joints care-
fully ½- to 1-inch wide and as shown in Figures 600-6, 600-7, and 600-8.
Note Figure 600-7 shows sealant system for corrosion control in mild environ-
ment; Figure 600-8, for more severe environments.
The steps for creating expansion joints are as follows:
1. Place sufficient joint material between the concrete surfaces to allow the
closed-cell foam-backing rod to come within ½- to 1-inch of the concrete
surface.
2. Pour or trowel on a flexible joint sealant to bring the joint up to the level of the
concrete surface.
3. Place 2-inch-wide, vinyl, electrical tape over the joint to provide a bond
breaker.
4. Place a ½-ounce glass mat, saturated with resin, over the tape.
5. Apply the corrosion coating system over the mat.
Additional Steps for Large Cracks. To repair larger cracks, fill them by pres-
sure injection. The steps for pressure injection are as follows:
1. Grind the crack into a V shape.
2. Select an appropriate size of copper tubing.
3. Drill holes along the crack 1/8-inch larger than the tubing and to the depth of
desired penetration.
4. Insert the tubing into the crack.
5. Grout the crack on the surface to seal it and hold the tubing in place.

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Fig. 600-6 Corrosion Control Treatment of Sealed Expansion Joints, Control Joints, and
Cracks in Concrete Foundations

6. Install a grease fitting in the first tube when the grout is cured.
7. Inject grout into the tube with a pump.
8. Allow the grout to flow out of the next tube until the color approaches the orig-
inal mixture to ensure removal of all contaminants.
9. Repeat the process, filling all tubes.

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Fig. 600-7 Corrosion Control Treatment of Exposed Expansion Joints in Concrete Integral
with Monolithic Floor/Lining System

Holes
This section provides information on filling both small and large holes.
Small Holes. During blasting, air pockets open in or just below the surface of most
formed concrete. There are two mixes for filling these holes.
• Resin-based material is the Company's preferred method of repair. Some are
powders mixed with the primer and trowel applied which gives a smooth
surface for good coating adhesion. Others are epoxy grouts.
• Portland-cement materials require expert installation and generally need an
additive to reduce shrinkage during cure and to improve adhesion to the old
surface. The problems with this cement are that it does not bond well to cured
concrete; does not cure well in thin layers; and usually leaves a carbonate layer
on the surrounding concrete which can, if not removed, cause coating failures.

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Fig. 600-8 Corrosion Control Sealing of Expansion Joints, in Concrete Integral with
Monolithic Floor/Lining System

Large Holes. There are two main choices of fill for larger holes, both of which need
special handling:
• Concrete - Undercut the hole to guarantee mechanical bonding or apply a
chemical bonding agent.
• Compatible resinous grout - Treat forms with a release agent for easy removal.
As formed resinous grouts usually cure with a glazed surface, abrasive blast or
grind this glazing to roughen it to ensure that the coating adheres well.

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Drain and Pipe Penetrations

Drain and pipe penetrations are almost as vulnerable to failure as expansion joints.
Usually, they are not concrete and have very different thermal coefficients of expan-
sion. Improper design can cause leaking at the penetrations.
For drains, see Figure 600-9. Figure 600-10 shows details of installing a corrosion-
control system for pipes.

Fig. 600-9 Floor System Termination at Floor Drain

In either case:
1. Dig a groove ¾-inches wide and ¼-inch deep around the drain or pipe
penetration.
2. Fill the groove with sealant.
3. Butt the corrosion control system against the sealant for mild environments or
extend it to the drain cover in more aggressive environments.

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Fig. 600-10 Corrosion Control Treatment of Pipe Penetration through Concrete Wall or Floor

650 Surface Preparation

The life of a coating is directly related to surface preparation.
After designing joints and penetrations and repairing all cracks, holes, and other
defects, establish the method of surface preparation necessary to clean away all
loose concrete, oil, grease, dust, laitance, grime, and other foreign materials.
There are several methods of surface preparation for coating concrete. The mechan-
ical methods—abrasive blasting, scarifying, and blastracking—produce the best
surface for coating adhesion.

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651 Pre-application Requirements

See Assessing and Repairing Concrete (above) for the four conditions required of a
concrete substrate to be ready to accept a coating.
☞ Caution Do not accept broom finishing as it can leave an irregular surface with
excess laitance; and, in the case of air-entrained concrete mixes, it can open large
holes at the surface.

652 Precleaning
To preclean a concrete surface, follow the ASTM D4258 method:
1. Remove:
– Dirt and caked grease manually or with an acid wash
– Grease and oils with low-foaming detergents
– Animal fats or vegetable oils with saponifying agents
2. Patch test to determine the best cleaning procedures for the surface.
Clean or remove the surface until it meets the pre-application requirements.

653 Mechanical and Chemical Cleaning

Abrasive-blast Cleaning
Abrasive-blast cleaning is the Company's preferred method of surface preparation.
Note There is additional information about abrasive-blast cleaning in Section
400; and, although that section relates to surface preparation for steel substrates,
some details are applicable to concrete.
Advantages:
• Gives high production rates for all surface configurations
• Leaves an excellent surface condition for coating
Disadvantages:
• Creates excessive dust and waste material as the abrasive breaks down

Blastracking
Blastracking is similar to abrasive blasting but uses metal shot instead of abrasive
Advantages:
• Produces comparable surfaces to abrasive blasting with less dust and waste
material
Disadvantages:
• Restricted to horizontal surfaces because it is a fairly large machine

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Scarifying (Air Hammer)

Scarifying is often the alternative when field or other conditions prevent blasting of
concrete surfaces.
Note A scarifier is an apparatus with steel hammers that hit a surface, removing
loose material.
Advantages:
• Produces an acceptable surface with less clean-up, set-up, and dust.
Disadvantages:
• Produces a rougher surface than abrasive blasting.

Acid Etching
Acid etching is the least acceptable cleaning method, but may be used if needed.
The steps for acid etching are:
1. Mix one part of concentrated hydrochloric acid with two parts water to form the
etching solution.
2. Brush the solution on the concrete.
☞ Caution If the etch does not produce a 60-grit, sandpaper-like profile, repeat
the etch.
Diluted acid permeates the concrete surface dissolving salts and other contami-
nants. There is, however, an undesirable side effect; as it dries, the acid deposits the
contaminants on the surface, adversely affecting the bond between the coating and
the concrete.

660 Application
Because of the complexity of coating concrete and the different systems and resins
available, it is impossible to have one uniform application procedure.

661 Recommended Process

The recommended application process is to:
1. Select the coating system and resin. Either refer to the Quick Reference Guide
(for mild environment) or obtain the assistance of the coating manufacturer and
the Company's concrete coating specialist (for other environments).
2. Request detailed application procedures from the manufacturer for the coating
selected.
3. Review application procedures with the coatings applicator and the coating
manufacturer, resolving differences until the procedure is acceptable to all.

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662 Reviewing an Application Procedure

Here are some points to consider when reviewing or writing an application procedure:
• Many concrete coating systems require a primer for optimum application
results.
• The temperature of concrete slabs should be between 50°F and 85°F when
coating; the slab's temperature must be 5°F above the moisture dew point.
• For optimum results from the application:
– Apply the primer coating out of direct sunlight.
– Apply the primer and topcoat when the slab's temperature is cooling rather
than rising.
• An order of cost (low to high) for coating systems is thin films, flake-
reinforced films, and laminate-reinforced films.
• An approximate order of cost (low to high) for resins is as follows: polyesters,
epoxies, novolac epoxies, vinyl esters, and polyurethanes.
• Epoxy resins are the easiest to apply, followed by novolac epoxy, polyester,
polyurethane, and vinyl ester.
• Polyester and vinyl ester require a final wax coat (mixture of wax and resin) to
obtain full surface cure.
• Thicker is not always better. All coatings and linings have a maximum allow-
able thickness.

670 Inspection
Inspection is an integral part of the quality of a coatings project. The following
references offer guidance about the degree of inspection needed and how to select a
quality inspector.
• Coatings Manual, Section 100
The inspection procedures for steel can be used for inspecting concrete, in most
cases.
• National Association of Corrosion Engineers RP0288, Inspection of Linings on
Steel & Concrete.
• American Society for Testing and Materials D453786, Procedures to Qualify
and Certify Inspection Personnel for Coating Work in Nuclear Facilities.
(Good information about qualifying any coating inspector.)
Some construction details in concrete may need particular attention from the
inspector.

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Concrete-to-Steel Interface
In addition to penetrations, other potential concrete-and-steel interfaces need
coating.
See Figure 600-11, Detail “A,” for one example of sealing a pedestal/pipe stand in a
concrete pit.

Fig. 600-11 Corrosion Control Treatment of Steel-to-Concrete Interface

680 References
The following publications give additional information for repairing and coating
concrete.
1. American Society for Testing and Materials. Standard Practice for Surface
Cleaning Concrete for Coating (R 1992). ASTM D4258. 1983.
2. ———. Standard Practice for Abrading Concrete (R 1992). ASTM D4259.
1988.
3. ———. Standard Test Method for Indicating Moisture in Concrete by the
Plastic Sheet Method (R 1993). ASTM D4263. 1993.
4. ———. Standard Practice for Determining Coating Contractor Qualifications
for Nuclear Powered Electric Generation Facilities. ASTM D4286. 1990.
5. ———. Standard Guide for Establishing Procedures to Qualify and Certify
Inspection Personnel for Coating Work in Nuclear Facilities. D4537. 1991.
6. ———. Standard Test Method for Pull-off Strength of Coatings Using Portable
Adhesion Testers. ASTM D4541. 1995.

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7. National Association of Corrosion Engineers. Monolithic Organic Corrosion

Resistant Floor Surfacing. NACE RP-03-76.
8. ———. Inspection of Linings on Steel and Concrete. NACE RP-02-88.
9. ———. Linings for Concrete Surfaces in Non-Immersion and Atmospheric
Services. RP-0591-91.

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