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Pacific States Protecto 401


Pacific States' primary wastewater lining material is the Protecto 401 ceramic epoxy lining. This novolac epoxy/ceramic quartz pigment lining is ideal for a variety of sewer and industrial waste applications. It has exhibited superior mechanical bonding strength and abrasion resistance while protecting ductile iron pipe and fittings against interior corrosion.

Application of the lining occurs in a low temperature controlled environment ensuring that the 40-mil lining will not develop any residual stresses. Adherence to strict specifications from surface preparation to inspection are observed. Upon completion of the lining process each pipe must pass a 2500 volt holiday detection test.

Unlike most other ductile iron pipe foundries, Pacific States applies the Protecto 401 where the pipe itself is produced. This gives Pacific States control of the quality of the workmanship and the production/delivery schedule.

Pacific States Protecto 401 Specification

Pacific States' Protecto 401 lined Ductile Iron pipe and fittings provide the maximum protection and the strength necessary to do the job in tough sewer pipe applications. Protecto 401 has successfully been used in hundreds of sanitary sewer applications and has been proven with both laboratory testing and years of actual sewer service on all sizes of Ductile Iron pipe and fittings.

Protecto 401 Ceramic Epoxy Lining was designed and is used as a protection for sanitary sewer conduits. This concentration of effort has resulted in performance unparalleled by other linings.

Protecto 401 has been, tested and withstood the following:

Salt Spray- Testing discontinued after 3,400 hours with no undercutting on a scribed Ductile Iron panel when measured using ASTM-B 117-73 and when rated using ASTM-D 714-56 (1974) evaluating degrees of blistering.

20% Sulfuric Acid- Testing discontinued after 2,200 hours with no effect when rated using ASTM-D 714-87 evaluating degree of blistering.

25% Sodium Hydroxide Immersion- @ 140° F. Testing discontinued after 3,500 hours, no effect when rated using ASTM-D 714-56 (1974) evaluating degree of blistering. Deionized Water Immersion @ 160°F. Testing discontinued after 2,400 hours with no effect when rated using ASTM-D 714-56 (1974) evaluating degree of blistering.

Protecto 401 is also resistant to a wide range of oils, grease, solvents, detergents and fuels which may be introduced into a sewer line.

Protecto 401 is applied to the interior of ductile pipe and fittings utilizing specialized application equipment and a stringent specification. The lining is designed to be applied at a nominal 40 mils thickness. A holiday detection test and a thickness test is performed to insure a sound chemically resistant protective lining for Ductile Iron pipe and fittings.

Protecto 401 is intended for use in domestic sanitary sewage lines. Requests for industrial sewer applications of Protecto 401 lined Pacific States Pipe and fittings should be made to a Pacific States Cast Iron Pipe Company for individual recommendations.

Suggested Specification for Protecto 401 Interior

  1. Condition of Ductile Iron Prior to Surface Preparation
    All Ductile Iron pipe and fittings shall have a high build protective lining on the interior and a bituminous coating on the exterior except for 6 inches back from the spigot end. The bituminous coating shall not be applied to the first 6 inches of the exterior of the spigot ends. All ductile pipe and fittings shall be delivered to the application facility without asphalt, cement lining, or any other lining on the interior surface. Because removal of old linings may not be possible, the intent of this specification is that the entire interior of the Ductile Iron pipe and fittings shall not have been lined with any substance prior to the application of the specified lining.
  2. Lining Material
    The material used for lining the pipe and fittings must have a successful history of protecting pipe lines in sewer service. The material must be a high build multi-component Amine cured Novalac Epoxy lining. The standard of quality is Protecto 401 Ceramic Epoxy. Any request for substitution must meet the following criteria and be accompanied by:
    1. The permeability rating when tested according to Method A of ASTM E-96-66, Procedure A with a test duration of 42 days as reported by an independent laboratory.
    2. A statement from the manufacturer of the submitted material attesting to the fact that a least 20% of the volume of the lining contains ceramic quartz pigment.
    3. A laboratory report containing test data for Immersion in Acids, Bases, and Deionized Water at elevated temperatures using ASTM-D 714-56 (1974) for the rating method. The report should also contain data on ASTM D-2794 Direct Impact and ASTM-G 53-77 Moisture and Ultraviolet Light Exposure.
    4. A statement concerning recoatability and repair to the lining.
  3. APPLICATION
    1. Applicator
      The lining shall be applied by a competent firm with a successful history of applying linings to the interior of Ductile Iron pipe and fittings.
    2. Surface Preparation
      Prior to abrasive blasting, the entire area which will receive the protective compound shall be inspected for oil, grease, etc. Any areas where oil, grease, or any substance which can be removed by solvent is present shall be solvent cleaned using the guidelines outlined in SSPC-1 Solvent Cleaning. After the surface has been made free of grease, oil or other substances, all areas to receive the protective compounds shall be abrasive blasted using compressed air nozzles with sand or grit abrasive media. The entire surface to be lined shall be struck with the blast media so that all rust, loose oxides, etc., are removed from the surface. Only slight stains and tightly adhering annealing oxide may be left on the sur face. Any area where rust reappears before coating must be reblasted to remove all rust.
    3. Lining
      After the surface preparation and within 8 hours of surface preparation, the interior pipe shall receive 40 mils dry film thickness of the protective lining. No lining shall take place when the substrate or ambient temperature is below 40 degrees Fahrenheit. The surface also must be dry and dust free. If flange fittings of pipe are included in the project, the linings must not be used on the face of the flange; however, full face gaskets must be used to protect the ends of the pipe. All fittings shall be lined with 40 mils of the protective lining. The 40 mils system shall not be applied in the gasket grooves.
    4. Coating of Gasket and Spigot Ends
      Due to the tolerances involved, the gasket area and spigot end up to 6 inches back from the end of the spigot end must be coated with 6 mils nominal, 10 mils maximum Protecto Joint Compound. This coating shall be applied by brush to ensure coverage. Care should be taken that the coating is smooth without excess buildup in the gasket groove or on the spigot end. All materials for the gasket groove and spigot end shall be applied after the application of the lining.
    5. Number of Coats
      The number of coats of lining material applied shall be as recommended by the lining manufacturer. However, in no case shall this material be applied above the dry thickness per coat recommended by the lining manufacturer in printed literature. The time between coats shall never exceed that time recommended by the lining material manufacturer. No material shall be used for lining which is not indefinitely recoatable with itself without roughening of the surface.
    6. Touch-Up & Repair
      Protecto Joint Compound shall be used for touch-up or repair. Procedures shall be in accordance with manufacturer's recommendations,
  4. Inspection and certification
    1. Inspection
      1. All Ductile Iron pipe and fitting linings shall be checked for thickness using a magnetic film thickness gauge. The thickness testing shall be done using the method outlined in SSPC-PA-2 Film Thickness Rating.
      2. The interior lining of all pipe and fittings shall be test ed for pinholes with a nondestructive 2,500 volt test.
      3. Each pipe joint and fitting shall be marked with the date of application of the lining system and with its numerical sequence of application on that date.
    2. Certification
      The pipe or fitting manufacturer must supply a certificate attesting to the fact that the applicator met the requirements of this specification, and that the material used was as specified, and that the material was applied as required by the specification.

Procedures for sealing cut ends and repairing field damaged areas of PROTECTO 401 lined ripe and fittings.

  1. Remove burrs caused by field cutting of ends or handling damage and smooth out the edge of the lining if rough.
  2. Remove all traces of oil, grease, asphalt, dust, dirt, etc.
  3. Remove any damaged lining caused by field cutting operations or handling and clean any exposed metal by sanding or scraping. Sandblasting or power tool cleaning roughening is also acceptable. It is recommended that any loose lining be removed by chiseling, cutting, or scraping into well adhered lined area before patching. Be sure to overlap at IPast 1" of lining in the area to be repaired.
  4. With the area to be sealed or repaired, absolutely clean and suitably roughened, apply a coat of Protecto Joint Compound using the following procedure:
    1. Mixing Procedure-Protecto Joint Compound is a 7to-1 (7:1) mix ratio. When mixed, it should contain 7 parts of the black activator and one part of the translucent blending resin. This can be accomplished by simply using the same container to dip out seven containers full from the large can and pouring one container full from the small can which contains the blending resin. This is the simplest and most accurate means for field mixing less than the kit provided. After the blending resin is added to the activator, the mixture should be thoroughly agitated. All activated material must be used within 45 minutes of mixing.
    2. Application of Material-After the material has been thoroughly mixed in a seven-to-one (7:1) ratio, it can be applied to the prepared surface by brush. Brushing is usually best, due to the fact that the areas are usually small. Practices conducive to a good coating are contained in the technical data sheet for Protecto Joint Compound.
  5. It is important to coat the entire freshly cut exposed metal surface of the cut pipe end. To ensure proper sealing, overlap at least, one inch of the lining with this repair material.

PROTECTO 401 JOINT COMPOUND TECHNICAL DATA

DESCRIPTION: A brushable Novalac Epoxy designed for use on the spigot ends and gasket areas of bells when pipes are lined with Protecto 401 Ceramic Epoxy.

LIMITATIONS : This material should be used on spigots and bells only after the pipe is lined with Protecto 401 Ceramic Epoxy. Protecto Joint Compound can be used over Protecto 401 er on bare substrate.
Do not apply Protecto 401 over Protecto Joint Compound.

SURFACE PREPARATION: The surface preparation shall be equal to the specifications for the project or as outlined in the touchup up procedure.

COVERAGE: Theoretical--1247 ft' per gallon at 1.0 mil dry film thickness.

DRY FILM THICKNESS: 8.0-10.0 mils per coat.

APPLICATION DATA

APPLICATION: Brush, Roll, or Airless Spray.

THINNING: Thin or clean up with Methyl Ethyl Ketone.

CLIMATE: Use this product only if the substrate temperature and ambient air temperature is above 40° F. and is expected not to decrease for at least two hours after application. Also, the substrate temperature must be 5° F. above the dewpoint for a period of at least two hours after application to avoid condensation occurring on wet paint.

DRY TIME:
TO HANDLE--8 hrs. at 80° F.
TACK FREE: 4 hrs. at 80° F.
TO RECOAT--4 hrs. at 80° F.
DRY HARD: Overnight


Note: Lower temperature, higher film build, and/or poor ventilation will retard dry time.

PHYSICAL DATA:
VOLUME SOLIDS: 77 % + 1 %
VOLATILE ORGANIC CONTENTS < 1.27 lbs. per gal. mixed unthinned

SAFETY DATA: See individual product label for safety and health data information. Individual Material Safety Data Sheets are available upon request.

Links

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