Aluminum Can Plant Wastewater Treatment Sump CPL Retrofit

Holiday shutdowns are the perfect time for retrofits of various facility systems. An international aluminum can manufacturer took advantage of Thanksgiving shutdown to retrofit three (3) wastewater treatment sumps at one of their plants. Process chemistry of nitric acid, hydrofluoric acid, sulfuric acid and caustic solutions destroyed all coatings, and had aggressively eaten into the concrete leaving exposed rebar in the walls.

Plastek Werks’ recommended a polypropylene Concrete Protective Lining (CPL) system as a total solution in all three concrete tanks. Two crews were assembled, allowing work to rotate in stages, allowing three (3) sumps to be completely relined and retrofitted, giving the facility a primary and secondary lining, meeting EPA mandates. The “overpour” method of construction was utilized for a quick turnaround time of 8 days – start to finish. The “overpour” method requires that all walls and floor receive a neutralization wash; then, rebar stubs or dowels are fastened into the concrete surfaces on a grid, sticking out 2.5”, with reinforcement wire tied to the rebar.

In the “overpour” application, CPL liner materials are placed smooth side against the internal formwork, with anchors facing existing concrete surfaces, wire reinforcement and rebar. An annular space between the CPL lined forms and the existing walls allows the flow of concrete with smaller aggregate to form the new pour. Cured, this “overpour” retrofit becomes mechanically tied into the existing and original structure.

Leak detection sensors allow monitoring 365 days/year, 24 hours/day. Extrusion welding by Plastek Werks certified plastic welding technicians play a critical role in providing a continuous leak proof lining system that transitions joints and seam with a molecular bond.