Case Histories
Steep Rock Gas Plant - Storm Water Pond
| Client | EnCana |
|---|---|
| Product | EF-1990 |
| Project Size | 66,000 sq.ft. |
| Completion Time | 16 days |
| Challenges | Endless rainfall |
Project Overview
The Steep Rock Gas Plant required a Storm Water Pond that would effectively contain site run off until the accumulated water could be environmentally tested and released.
An important and unusual requirement for this project was containment that was tough enough to withstand local wildlife travel. The coating also needed to be UV resistant and able to mold to the substrate so stress on the sizable liner was minimal.
After researching other products the Encana Engineering team selected RMC’s signature EF-1990 coating. The decision was based on the toughness and durability of EF-1990. Other products would puncture with animal traffic, deteriorate with UV exposure or separate over time. RMC was also selected because of professional installations on previous projects.
The endless rainfall at the Steep Rock site became a challenge for RMC. The rainfall created significant site run off with large amounts of water accumulating in the pond. The standard application pattern for a bowl of this size is to start spraying from one edge, continue through the bowl and finish at the other edge. The amount of water collection in the pond did not allow this and an alternate approach was needed. RMC pumped the water out of the bowl and started by spraying only the bottom or bowl area. Once this portion was completed, the bowl contained the rain and run off waters while the crew could complete the edges of the pond.
The 66,000 sq ft Storm Water Pond was lined with EF-1990 in 16 days to the complete satisfaction of the client and within the project scheduled time.
Fort McMurray Tar Island - Collection Pond
| Client | Suncor |
|---|---|
| Product | EF-1990 |
| Project Size | 130,000 sq.ft. 3.5 acres |
| Completion Time | 14 days |
| Challenges | Crucial timeline Rainfall |
Project Overview
Suncor consulted RMC to help find a cost effective and efficient alternative method to using large earth moving equipment to clean up bitumen from Collection Ponds.
RMC proposed lining the pond with a very tough and smooth spray-on coating that could simply be cleaned up by washing the area with pressure washers. EF-1990 was selected because it could easily withstand the intense pressure from the fire hoses and gritty water used to wash the liner. Plant operations personnel can now wash the area with pressure washers/fire hoses, collect the bitumen, remove it with vacuum trucks and then have it recycled. This solution eliminated the need to have earth moving equipment and provided an effective and efficient way of removing the collected bitumen.
Suncor’s construction schedule was a very tight 15 day shutdown. Rain during the construction phase created project delays resulting in only 10 days for RMC to spray 130,000 sq. ft. Time was running out and the project needed to be completed on time. To ensure completion, RMC set up an environmental air structure (20,000 sq ft) on the site so the crew could pre-spray long strips of coating to be installed later. The environmental air structure was the perfect solution for rain delays and scheduling concerns. RMC sprayed the majority of the pond coating onto 100 ft x 15 ft geotextile strips. Spraying inside allowed perfect working conditions for this enormous project. Once the weather and scheduling allowed, the polyurethane strips were moved into the pond and placed with a skidsteer. The strips were then sprayed together to create a monolithic liner that was 3.5 acres in size!
To guarantee the completion date, RMC was installing their pre-sprayed strips while the earth moving equipment was completing the pond. RMC completed this sizable project one day after the last earth mover left the site and one day ahead of schedule!
Calgary Zoo - Special Enclosure Stingray Pond
| Client | Calgary Zoo |
|---|---|
| Product | EF-1990 |
| Project Size | 1500 sq.ft. |
| Completion Time | 2 days |
| Challenges | Environmental factors |
Project Overview
The Calgary Zoo needed an environmentally friendly product that was compatible with heated salt sea water in a feature showcasing sea rays, turtles and sharks. This was a fun and aesthetically beautiful project. The Enviro friendly EF-1990 met all the environmental criteria and was able to accommodate the structure design including spraying around features such as manufactured rocks.
A 1500 sq ft. pond was constructed of plywood and built in sections to enable dismantling and moving at a later date. To enable the dismantling, RMC installed a special joint system that allows access to the bolting system while still maintaining a complete leak free containment.
One of the challenges on this project was to coordinate the installation of the liner system to the Stingray pool (base plywood) with the schedule of the neighbouring Baby Elephant and his mother. Clear instructions were given to NOT upset these interesting and temperamental elephants in their daily routines. Working cooperatively with the Staff at the Calgary Zoo, RMC quickly completed the spray in liner. This minimized disruption to the elephant routines and allowed the Baby elephant to continue enjoy playing outside with visiting children.
Municipal District of RockyView - Dalroy Sewage Transfer Station
| Client | MDRV |
|---|---|
| Product | EF-1988 |
| Project Size | 3600 sq.ft. |
| Completion Time | 2 days |
| Challenges | Confined space |
Project Overview
This state of the art Sewage Transfer Station required a coating product capable of protecting the concrete from the corrosive atmosphere of Hydrogen Sulphide gas and liquid sewage products. EF-1988 was the perfect choice for this project as it is specifically formulated for use in sewage systems. It provides superior containment as well as protects the concrete from the corrosive action of Hydrogen Sulphide gases.
The 8m cubed vault was poured and Hydro tested. To prepare the concrete for polyurethane coating, water was removed and the vault dried using large fans, heaters and dehumidification equipment. RMC sandblasted the walls, ceiling and floor to remove all latents and then applied a specially formulated primer.
Once the primer dried and set, the crew spray applied a 100 ml coating of EF-1988. All vault interior walls, floor and ceiling were coated with a double layer of EF-1988 to ensure perfect coverage and protection.
The EF-1988 is a product specially designed for use in potable water or sewage system applications. This vault being contained with EF-1988 is expected to have a very long life expectancy.
Ashland Chemicals - In-Ground Concrete Wall Tank Farm
| Client | Ashland |
|---|---|
| Product | EF-1990 |
| Project Size | 13,000 sq.ft. |
| Completion Time | 3 days |
| Challenges | Timeline |
Project Overview
RMC assisted Ashland Chemical with finding an efficient and economical coating for their chemical tank farm. The tank farm required a very tough product to withstand various chemical spills, heavy daily traffic and adverse weather (freeze/thaw) conditions. RMC’s product met all technical requirements for a chemical storage facility and the efficient one coat spray on system facilitated a tight construction schedule.
The tank farm was a 13,000 sq ft in-ground concrete walled area. The concrete containment area was poured in place and, once cured, RMC sand blasted the walls and floor to remove latents from the concrete. A standard spray of 100mls of EF-1990 Polyurethane coating was then applied to the walls, floors and to the concrete tank bases.
Within 1 hour of applying the coating, the surface was cured enough that workers could resume installing the tanks and piping for the project. Other products would not be able to accommodate such a unique site and/or accommodate the quick setting times needed in tight project schedules.
Utilizing the EF-1990 coating guaranteed the client complete environmental protection for chemical storage and the fast setting time maximized site productivity and scheduling.
Petro Canada - Produced Water Pond
| Client | Petro Canada |
|---|---|
| Product | EF-1990 / ET-2000 |
| Project Size | 10,000 sq.ft. |
| Completion Time | 6 days |
| Challenges | Primary & Secondary Containment |
Project Overview
Petro Canada required coating under, around and inside of this Produced Water Pond enclosure. For this unusual and interesting project EF-1990 was selected so the entire area could be completely enveloped. RMC was able to provide both Primary and Secondary containment using the ET-1990 for the Secondary containment and the ET-2000 for the Primary containment.
Completely enveloping a multi faceted liner system in 3 concrete settling ponds was a challenge. Extensive consultation was required with the engineering team to finalize an optimum approach. Following the initial excavation, RMC installed a 150ml liner on the substrate; then a layer of sand was added, followed by leak detection piping and another layer of sand. The concrete slab and walls for the pond were then poured. Once completed, the initial liner was wrapped over the sand and attached back to the exterior walls creating 100% enveloped concrete holding cells.
The final step was coating the interior holding cell walls with ET-2000. This product is similar to the EF-1990 used on the exterior except that sand is impinged into the polyurethane to create an extremely durable coating. The final outcome of the ET-2000 is a product that has similar characteristics to concrete (hardness) but is also a very effective elastomeric containment system.
RMC and Petro Canada’s extensive collaboration created an innovative design and timely project scheduling that resulted in successful pond containment.