Novolac Epoxy Coatings Provide Secondary Containment

Novolac (Novolak) Epoxy Coatings for Chemical Storage Vault

The word "epoxy" is used too much. Even architects and general contractors don't realize how specialized many coatings materials can be. While most general purpose, epoxy coatings afford a high level of chemical resistance to the concrete they protect, a special class of epoxies, called Novolac, provides extremely high chemical resistance. Novolac epoxy resins increases resistance to many acids and solvents, though these coatings often have lower flexibility than other coatings.

While Novolacs can be incorporated into a decorative coating system (such as quartz or decorative chip), they are more typical of solid color epoxy floors and are often completed in high-build systems (greater than 20 MILS dry film thickness).

Chemical Storage Vault Coated with Novolac

Early in 2014, our Pennsylvania operation was asked to bid a job where a special hazardous materials vault was being built into the company’s leased space in Lancaster. Our contacts at High Associates asked us to specify a system which would provide at least 72 hours of secondary containment for a chemical manifest that was two pages long.

Two of our chemical manufacturers provide Novolac epoxy coatings. They each have extensive chemical resistance charts that outline how each of their Novolac primers, body coats, and top coats will perform when exposed to a specific chemical under multiple conditions. The conditions are timeframes and typically break down into the following:

• Not recommended for exposure to this chemical.
• Short term/immediate splash spills (not to exceed 2 hours).
• Long term splash spills (not to exceed a normal 8-10 hour work shift without cleanup).
• Short-term immersion (not to exceed 72 hours).
• Long-term immersion (continuous exposure to a chemical).

Having reviewed the customer’s chemical manifest, we determined only one of our vendor’s Novolac epoxy systems would withstand the potential spill and necessary containment of sodium hypochlorite (12.5%). This chemical is very corrosive to most coatings and is extremely destructive on unprotected concrete.

The remainder of the chemicals did not pose any issue for any of our Novolac epoxy systems.

In addition to protecting the floor of the chemical vault, we also had to transition up the concrete walls for an additional 24 inches.

Our system for this project consisted of Rock-Tred Novolacs comprised of an 11 MIL primer, 14 MIL body coat with a full broadcast of sand, and a 25 MIL top coat. The walls were primed with an Elasti-Poxi membrane and then coated with the same system as the floor. The transition from floor to wall was accomplished using a 2” cant cove.

Once installed, the H-Vault was fitted with a special “drawbridge” over a containment pit that can spring shut and seal the entryway into the room if a spill is detected.

Where Else are Novolac Epoxies Used?

Some other typical locations and uses for Novolac epoxies are:

• Chemical storage
• Food processing
• Drain pit linings
• Dairy and cheese rooms
• Tank linings
• Battery storage
• Fork truck battery recharge stations
• Laboratories

Our other recent Novolac epoxy projects have included:

Dairy farms – At the Ben Stoltzfus Farms, we installed the Novolac epoxies to protect against the strongly acidic cleaners used with the stainless steel tanks.

Cheese processing – At Cumberland Valley Creamery, the acidic nature of the cheese making process is very hard on traditional epoxy coatings. Our Novolac epoxies protect this new Mechanicsburg, PA business.

Battery storage/charge stations – For Conewago Enterprises, we recently completed almost 6,000 square feet of Novolac epoxy coatings that were reinforced with sand to withstand the heavy abuse from forklifts.

Distillery production – At the Hotel Fulton Distillery, we installed a high build, Novolac epoxy system with an integrated cove base.