Welcome to Poly Coating Solutions
At Poly Coating Solutions, we specialize in providing top-tier wastewater treatment solutions and concrete repair techniques for the wastewater, sanitary sewer and potable water industry. With years of expertise and a commitment to quality, we serve municipalities, contractors, and industrial clients in need of reliable, long-lasting solutions for the complex challenges of underground infrastructure.
Our services focus on restoring the structural integrity of aging systems while preventing further deterioration caused by harsh environmental conditions, corrosive chemicals, and constant water exposure. From protective coatings for infrastructure that ensure the longevity of pipes, tanks, and treatment facilities, to advanced concrete repair methods that extend the life of critical infrastructure, we offer a comprehensive range of services designed to minimize downtime and improve system performance.
By combining cutting-edge technology, industry-leading products, and skilled craftsmanship, Poly Coating Solutions delivers cost-effective, sustainable solutions that you can trust. Whether it's rehabilitation, repair, or preventive maintenance, we are dedicated to keeping your water/wastewater and systems running smoothly and efficiently for years to come.
Explore our website to learn more about our services and how we can help safeguard the future of your infrastructure.
Want to see examples of our past projects? Check out our Gallery to see some of the projects we have completed for our satisfied clients.
How Concrete Rehabilitation and Coatings Work in the Wastewater and Sanitary Sewer Industry
The wastewater and sanitary sewer industry plays a crucial role in maintaining public health and environmental safety by managing the collection, treatment, and disposal of wastewater. Over time, the infrastructure used in these systems—such as pipes, tanks, and treatment facilities—can deteriorate due to constant exposure to harsh elements like water, chemicals, and abrasive materials. To extend the lifespan of these vital assets, concrete rehabilitation and protective coatings for infrastructure are essential solutions.
Concrete Rehabilitation: Restoring Structural Integrity
Concrete in wastewater and sanitary sewer systems often face significant deterioration from the corrosive effects of wastewater, hydrogen sulfide, and other chemical agents. Additionally, structural damage can occur from ground movement, age, or improper installation.
Concrete rehabilitation involves a series of concrete repair techniques to repair and restore the concrete’s original strength and functionality. The process typically begins with a thorough inspection to assess the extent of the damage. Once the condition is evaluated, the following techniques may be used:
Surface Preparation: This step involves cleaning the surface to remove dirt, debris, and any loose or deteriorated material. Sandblasting, high-pressure water cleaning, or chemical treatments are often used to ensure a clean, stable surface.
Crack Repair: Cracks in concrete are common, and if left untreated, they can exacerbate over time. Various methods, including epoxy injection or the use of crack fillers, help to seal these cracks and restore the concrete’s structural integrity.
Surface Repair: Once cracks are sealed, damaged sections of concrete may need to be patched or resurfaced. This can involve applying a high-strength repair mortar or other specialized materials designed to bond securely with the existing concrete and provide a durable surface.
Reinforcement: In cases where the concrete has suffered extensive structural damage, additional reinforcement may be necessary. Steel rebar, carbon fiber, or other composite materials are often used to provide extra support and ensure the long-term strength of the concrete.
Coatings: Protecting Against Future Damage
Once the concrete has been rehabilitated, coatings are applied to further protect the surface and enhance its durability. Coatings act as a barrier between the concrete and the harsh environmental factors present in wastewater and sanitary sewer systems, helping to prevent corrosion, abrasion, and chemical attack.
Epoxy Coatings: Epoxy-based coatings are widely used in the wastewater industry due to their ability to resist chemical attack, moisture, and wear. They provide a strong, impermeable layer that protects the underlying concrete from the corrosive effects of wastewater and sewage.
Polyurea Coatings: These coatings are known for their flexibility and resistance to abrasion. Polyurea coatings are often used in environments with varying temperatures and mechanical stress, as they can accommodate slight shifts in structure without cracking.
Cementitious Coatings: These coatings are made of a blend of cement and chemical additives. They are ideal for areas that require both protection and restoration. Cementitious coatings are applied in a thick layer, offering a strong, durable barrier that also helps to fill small cracks and voids in the concrete.
Why Concrete Rehab and Coatings Are Critical
The wastewater and sewer infrastructure are exposed to a constant flow of corrosive substances, including sewage, chemicals, and sulfuric acid produced by bacteria. Over time, these substances degrade concrete and can lead to costly repairs, system failures, and safety hazards. By investing in concrete rehabilitation and protective coatings, municipalities and private entities can:
Extend the life of their infrastructure: Proper repairs and coatings can add decades to the service life of pipes, tanks, and other facilities, reducing the need for costly replacements.
Reduce downtime: Rehabilitation work can often be completed quickly and efficiently, minimizing system downtime and service disruptions.
Improve system efficiency: Well-maintained infrastructure operates more efficiently, reducing energy consumption and maintenance costs.
Enhance safety: Preventing cracks, leaks, and system failures helps to protect public health and environmental safety.
In essence, the combination of concrete rehabilitation and coatings offers a proactive approach to maintaining the integrity of wastewater and sanitary sewer systems. These wastewater treatment solutions help to address existing damage while preventing future issues, ensuring that critical infrastructure continues to function effectively, efficiently, and safely.
The cost of treating water that leaks into the sewer system, often referred to as inflow and infiltration (I&I), varies widely depending on several factors, including the size and location of the wastewater treatment plant, the severity of the leakage, and the plant's capacity to manage and treat excess water. While providing a precise dollar amount is challenging without specific details, we can break down some general factors that contribute to the cost:
1. Increased Treatment Volume
Leaked water adds unnecessary volume to the treatment system, which means more water needs to be processed. This results in:
- Higher operational costs for pumping, treatment, and disposal.
- More chemical usage (e.g., for disinfection, coagulation, etc.), which adds to the treatment cost.
- Energy costs associated with running pumps, aerators, and other equipment to treat the additional volume.
2. Strain on Infrastructure
Excess water entering the sewer system can overwhelm treatment facilities, causing:
- Overflows or bypasses, which may result in costly fines or regulatory penalties if untreated water is discharged into the environment.
- Increased maintenance to deal with clogging, corrosion, and the need for repairs to damaged or overburdened equipment, potentially requiring concrete repair techniques to restore the infrastructure.
3. Cost Per Gallon
According to some industry estimates, the cost of treating wastewater can range from $0.50 to $3 per thousand gallons treated, depending on the plant's size, efficiency, and location. When water leaks into the system, treatment plants must process additional gallons that they wouldn't normally have to. If 1 million gallons of water leaks into the system every day, the treatment plant may be spending $500 to $3,000 per day just to treat that excess water.
4. Long-Term Capital and Operational Costs
In addition to the immediate operational costs, long-term solutions may be required, such as:
- Infrastructure upgrades to prevent or reduce infiltration, such as repairing aging pipes, relining sewer systems, or installing new monitoring systems. Protective coatings for infrastructure can also play a vital role in extending the life of these systems.
- Wastewater treatment solutions to handle increased volume or mitigate the impact of excess water.
Example:
Imagine a small to mid-sized plant in the U.S. that treats about 5 million gallons per day (MGD) on average. If infiltration increases that volume by 10%, it would require an additional 500,000 gallons per day to be treated. If the plant’s treatment cost is $1 per 1,000 gallons, this would mean an extra $500 per day in operating costs. Annually, that could add up to $182,500.
Other Cost Implications
- Environmental costs: Leaks may lead to increased runoff into local bodies of water, affecting aquatic ecosystems and water quality, leading to additional costs for environmental monitoring or mitigation measures.
- Regulatory compliance: Regulatory bodies may impose fines or penalties if water leaks are not identified and addressed, which can add significant costs beyond just treatment.
Total Cost Impact:
Ultimately, the cost of treating water that leaks into the sewer system is not only a matter of increased operational expenses but also involves long-term investments in infrastructure repairs, system monitoring, and regulatory compliance. For larger cities or regions with aging infrastructure, these costs can amount to millions of dollars annually.
Summary
While the exact cost varies by region and system, treating excess water due to sewer leaks can range from a few hundred thousand dollars to several million dollars each year, depending on the severity of the problem and the size of the system involved. Effectively managing inflow and infiltration is critical to reducing unnecessary costs and improving the sustainability and efficiency of wastewater treatment systems.
Poly Coating Solutions
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