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Concrete Aeration Basin Restoration: Fiberglass-Reinforced Lining System
Chemical Plant Wastewater Center
Chemical Plant Wastewater Center
The Problem
Severe Concrete Loss and Through-Porosity in a Large Basin
Length
120 ft
Width
40 ft
Height
35 ft
The basin had sustained severe concrete loss and contamination. A large number of 'worm holes' throughout the basin surface created through-porosity in the substrate.
Why Fiberglass Reinforcement
A straight coating application would bridge the holes but remain unbacked and vulnerable to hydraulic pressure from behind. A fiberglass-reinforced composite system was specified to create a structural membrane spanning the voids rather than simply covering them.
Specification
Fiberglass-Reinforced Epoxy Composite — 140 Mils Total DFT
Substrate
Concrete
Total DFT
140 mils
Reinforcement
1.5 oz, 60" Fiberglass Cloth
Surface Preparation
Full surface blasted with black beauty to remove failed concrete and contamination. Cracks and expansion joints filled with epoxy crack filler and allowed to fully cure — creating a deliberate break layer to prevent stress cracks from propagating through to the coating surface.
Stage 1 — Penetrating Primer
20-mil penetrating primer spray applied over the full surface.
Stage 2 — Hang Coat + Fiberglass
40-mil hang coat spray applied to receive the fiberglass reinforcement. 1.5 oz, 60-inch wide fiberglass cloth laid into the wet hang coat and wet out by hand across the full basin surface.
Stage 3 — Cover Coat
40-mil cover coat spray applied to fully wet out the fiberglass.
Stage 4 — Finish Coat
40-mil finish coat completing the system to 140 mils total DFT.
The Result
Basin #4
31 Days
Basin #2
26 Days
High-performance epoxy systems for industrial repair and protection.
