City of Pflugerville Upper Gilleland Creek WWTP Expansion, Concrete Coatings—Field Observations from the Owner’s Team

Extending the life of concrete structures within a wastewater collection and treatment system is a critical element to the life-cycle cost of the infrastructure assets. Many different types of concrete protection systems have been developed, one being epoxy coatings to provide a corrosion barrier to prevent wastewater gasses from corroding the structural concrete. The City of Pflugerville has recently completed construction of an expansion to the city’s Upper Gilleland Creek Wastewater Treatment Plant. The expansion included 12 wastewater manholes, an influent lift station, and headworks structure, and all were protected by an epoxy coating system. Each of the coating application steps is being evaluated in this paper, and some recommendations are provided. The two different epoxy systems (one being 100% solid epoxy sprayed with plural component spray equipment and the second being solvent cured epoxy sprayed with conventional spray equipment) are compared for constructability and efficiency of coating significant structures.