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Annual Report, Research and Technology Development Division, Japan Sewage Works Agency (Fiscal 2010)

Title Total project duration

Post-evaluation on Newly Developed Technologies Based on Existing Plants Performance - Anti-Corrosive CoatingFY2010-FY2012 Fiscal year 2010

1. Purpose In the history of construction with the concrete anti-corrosive coatings, the durability of the coating has been improved by developing coating materials/auxiliary agents and construction techniques. However, a report indicates that adequate durability has not been fully established, as seen in failure cases in some wastewater treatment plants that are less than 10 years old. A follow-up study was conducted on existing plants constructed with anti-corrosive coatings, to evaluate the resistance to erosion. This study aims to further improve the durability of anti-corrosive coatings by summarizing issues on the design and construction technique from failure cases, and to reduce the life cycle costs for concrete structures in wastewater treatment plants.
Edge se ction: a bo rder area of 2. Results of this fiscal year anti-corrosive co ating surf ace This year, the first year of the study, a Arris sectio n: a co rner area where wall questionnaire survey was conducted among surfaces intersect Edge section sewage works entities and associated Arris section companies in construction techniques for anti Wall Section -corrosive coatings. We received answers from 13.7% 21.0% about 600 sewage works entities and 87 Entire area associated companies and organizations. Figure 1 shows the results from the questionnaire among the sewage works 21.0% entities, indicating which section of the anti 44.4% -corrosive coating surface had a failure in sludge treatment facilities of the wastewater treatment plants. The percentages of sections where deterioration was observed were about 20% in both edge and arris sections, over 40% Figure1. Failure sections of antiin a wall section, and 10% in an entire area of corrosive coating the coating layer. Similar trends were observed in wastewater treatment facilities, less than 1 year where anti-corrosive coating is mainly applied 1.6% between the receiving well and the primary 1 to 2 years sedimentation tank. 3.9% 2 to 3 years Using results from the questionnaire among 16.3% 14.0% associated companies, Figure 2 summarizes 3 to 5 years the failure of paint type anti-corrosive coating with epoxy resins by service periods, from the 5 to 7 years time of construction to the time on which the 16.0% failure occurred (observed). Many cases of 33.5% more than 7 failure occurred shortly after the years 14.8% construction; about 50% of all failures unclear occurred within two years from the time of construction, and about 80% of all failures occurred within 5 years. For other types of resins, the failure percentage within 5 years Figure2. Time on which failure occurred for EP resin coating was higher than that of epoxy resin. From these questionnaire answers, it was

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Annual Report, Research and Technology Development Division, Japan Sewage Works Agency (Fiscal 2010)

confirmed that there are many cases of failure within 5 years after the construction when painting type anti-corrosive coating was applied, and that failure tends to occur most often in the edge and corner sections of the coating surface. Hence, it is necessary to research carefully more appropriate treatment methods for those sections. 3. Summary From the questionnaire answers regarding failure cases of anti-corrosive coatings, it was confirmed that there are many cases of failure within 5 years after the construction when painting type anti-corrosive coating was applied, and that failure tends to occur most often in the edge and corner sections of the coating surface and around trims. In order to improve the quality of anti-corrosive coating techniques, it is necessary to carefully research appropriate treatment methods for edge and corner sections and to reflect the results in the revision for the next anti-corrosive guidelines. It is required to convey this knowledge to related companies and organizations.

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