ARMORTHANE CASE
STUDY: RESURFACING
A 35-YEAR-OLD
WASTEWATER
FILTER BASIN
ARMORTHANE CASE
STUDY: RESURFACING
A 35-YEAR-OLD WASTEWATER FILTER BASIN
A wastewater treatment plant in Georgia, USA, needed to rehabilitate a 35-year-old concrete filter basin that was deteriorating after decades of service. We were tasked with restoring the basin’s integrity to be able to withstand constant exposure to water and harsh sewage chemicals; the concrete structure had developed cracks, surface wear, and areas of chemical attack from years of exposure to chlorinated water and hydrogen sulfide gases. The restoration was needed in the midst of an ongoing upgrade to the infrastructure, which required removing sections of the basin walls to install new effluent troughs, leaving fresh concrete patches that needed protection. We resurfaced and lined the entire basin with a thick, spray-applied ArmorThane polyurea coating, creating a seamless, durable barrier against moisture, chemicals, and physical wear for 35 more years or more of operation.
PROJECT OVERVIEW:
REPAIRING AGING
WASTEWATER
INFRASTRUCTURE
PROJECT OVERVIEW: REPAIRING AGING
WASTEWATER INFRASTRUCTURE
PROJECT OVERVIEW: REPAIRING
AGING WASTEWATER
INFRASTRUCTURE
The filter basin is a critical component of the plant’s treatment process, collecting and filtering millions of gallons of wastewater. After 35 years, the concrete basin was well-worn and showing its age. There were visible cracks and spalling, and prior coatings (if any remained) were failing. The newly installed troughs for improved water flow also had to be waterproofed to integrate with the basin. This scenario presented several challenges typical of wastewater infrastructure rehabilitation, and these challenges meant they needed a high-performance coating system that bonds tenaciously to old concrete, cures quickly to minimize downtime and offers long-term protection against a harsh wastewater environment.
THE APPLICATION PROCESS
The first step of the application process was surface preparation. We prepared the 35-year-old concrete using grinding tools that can remove old coatings, grime, and any weakened top layer of concrete. In doing so, the surface is also modified for optimal coating adhesion by controlling the surface roughness. After grinding we thoroughly cleaned the basin to eliminate any remaining dust and debris, after which, we applied a primer to all prepared surfaces. The primer soaked into the concrete’s pores and chemically bonded to it, which sealed the substrate and promoted excellent adhesion for the polyurea base coat. With the concrete now sound and sealed we next moved on to applying the main layer of the system.
We sprayed a thick layer of our polyurea coating onto the basin floor and walls, as well as the interior of the new effluent troughs. Applying the coating with high-pressure spray equipment allowed us to create a uniform liner covering every corner, curve, and joint, and because polyurea cures extremely fast (starting in as little as seconds), it rapidly builds up to a durable film and doesn’t drip or sag on vertical surfaces. The resulting coating would now shield the concrete from sewage chemicals, like from acidic biogas byproducts to chlorine, preventing those agents from reaching the concrete surface. Polyurea’s inherent abrasion resistance also means it can withstand the constant scouring of water flow and sediment, significantly reducing future wear.
We sprayed a thick layer of our polyurea coating onto the basin floor and walls, as well as the interior of the new effluent troughs. Applying the coating with high-pressure spray equipment allowed us to create a uniform liner covering every corner, curve, and joint, and because polyurea cures extremely fast (starting in as little as seconds), it rapidly builds up to a durable film and doesn’t drip or sag on vertical surfaces. The resulting coating would now shield the concrete from sewage chemicals, like from acidic biogas byproducts to chlorine, preventing those agents from reaching the concrete surface. Polyurea’s inherent abrasion resistance also means it can withstand the constant scouring of water flow and sediment, significantly reducing future wear.
THE RESULTS
The outcome of the project was a fully rehabilitated filter basin ready to serve for many more years; our polyurea lining system transformed the 35-year-old concrete basin into a resilient, leak-proof container for wastewater processing.
The durable polyurea coating shielded the underlying concrete from further chemical or physical damage, significantly extending the basin’s useful life. The basin was now also water-tight, preventing sewage leaks that could contaminate the environment. Moreover, the seamless polyurea surface was now easier to clean and inspect, and its toughness reduces the frequency of repairs. The facility saved significant time and money and the filter basin was back in operation swiftly and with minimal disruption.
The durable polyurea coating shielded the underlying concrete from further chemical or physical damage, significantly extending the basin’s useful life. The basin was now also water-tight, preventing sewage leaks that could contaminate the environment. Moreover, the seamless polyurea surface was now easier to clean and inspect, and its toughness reduces the frequency of repairs. The facility saved significant time and money and the filter basin was back in operation swiftly and with minimal disruption.
latest news & bLOGS
FREQUENTLY ASKED QUESTIONS
Wastewater infrastructure is best protected by using high-performance protective coatings or liners. For example, spray-applied polyurea coatings create a seamless barrier on concrete surfaces. This prevents corrosive sewage chemicals and moisture from contacting the concrete; by sealing cracks and forming a waterproof layer, coatings stop leaks and dramatically extend the life of tanks, basins, and pipes.
Yes. Polyurea coatings are formulated to resist a wide range of chemicals found in wastewater treatment, including acids, bases, sulfates, and disinfectants. Once cured, polyurea forms an inert, dense film that withstands continuous exposure to harsh sewage gases and liquids. Its chemical resistance makes polyurea ideal for protecting concrete in clarifiers, digesters, and filter basins where other materials would more quickly corrode or weaken over time.
A properly applied polyurea coating can last many years – often decades – in aggressive wastewater environments. Its lifespan depends on factors like coating thickness, formulation, and service conditions, but polyurea’s durability is well-proven. Routine inspections and maintenance can further extend its life, but little to none are needed. That’s because in practice, polyurea liners have remained intact and protective for 20+ years, outlasting traditional paint or epoxy coatings.
IN CONCLUSION
At ArmorThane, we pride ourselves on extending the life of critical infrastructure through our advanced surface technology. This Georgia wastewater filter basin rehabilitation exemplifies our commitment to qualify and broad-scope expertise that allowed us to act quickly, with an effective solution to every problem. If you want to learn more, consider reading more of our case studies, or contacting us directly to get started on your next coatings project!
