Secondary Containment Panels With Factory-Applied Polyurea Seams
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Solution Overview
Problem
Conventional secondary containment systems for above-ground fuel and chemical storage tanks face significant challenges due to wastage of polyurea coating material during outdoor application, inefficiencies in transportation, and complexity in equipment management, leading to high costs and environmental issues.
Innovation Solution
Manufacturing secondary containment panels in an environmentally controlled indoor facility using a computer-controlled robotic sprayer to apply polyurea coating uniformly onto geotextile fabric substrates, reducing wastage and simplifying onsite installation by prefabricating panels with uncoated edges for seamless assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If polyurea coating is sprayed onto geotextile fabric outdoors in the field, then the secondary containment system can be installed onsite, but a significant amount of coating material is wasted due to wind and rain dissipation
Solution Approach 1:
The patent applies preliminary action by pre-applying the polyurea coating to the geotextile fabric in a controlled factory environment before transportation and onsite installation. This allows the coating to be applied under optimal conditions without weather interference, eliminating material waste from wind and rain dissipation during field application.
Solution Approach 2:
The patent extracts the coating application process from the onsite installation sequence and performs it separately in a controlled factory setting. This separation allows the coating to be applied under ideal conditions while the onsite installation focuses only on assembling the pre-coated panels, resolving the contradiction between onsite capability and material waste.
2Ease of manufacture
If polyurea coating is sprayed from a distance of several feet to create a stippled slip-resistant surface, then the surface provides slip resistance, but coating material dissipates and misses the fabric entirely
Solution Approach 1:
The stippled slip-resistant surface is created during factory pre-coating before field installation. The controlled factory environment allows for precise spray application at the required distance to form the stippled pattern without material loss from wind dissipation, achieving both surface functionality and material efficiency.
Solution Approach 2:
The factory environment serves as a controlled, inert atmosphere free from wind and weather interference. This allows the spray coating to be applied at the necessary distance for stippled pattern formation without the harmful dissipation that occurs in outdoor conditions, resolving the contradiction between surface texture creation and material waste.
3Adaptability or versatility
If large amounts of polyurea coating and applicator equipment are transported to and from the secondary containment site, then the coating can be applied onsite, but the complexity and expense of installation increases
Solution Approach 1:
The patent extracts the coating application operation from the onsite installation process and relocates it to a factory setting. This eliminates the need to transport bulky coating materials and applicator equipment to and from the secondary containment site, significantly reducing transportation complexity and installation expense while maintaining the ability to provide coated panels onsite.
Solution Approach 2:
By performing the coating application in advance at the factory, the patent eliminates the need for complex onsite coating equipment and material handling. The pre-coated panels are simply transported and installed, transforming a complex multi-step onsite process into a simple assembly operation.
4Ease of operation
If conventional secondary containment panels are assembled and installed onsite with outdoor coating application, then the system can be deployed at the storage tank location, but the evenness and uniformity of coating coverage varies tremendously
Solution Approach 1:
The coating is applied in advance in a controlled factory environment where conditions can be precisely controlled to ensure uniform application. This preliminary coating step eliminates the variability caused by outdoor conditions during onsite installation, achieving consistent coating quality while maintaining deployability at the storage tank location.
Solution Approach 2:
The factory environment provides a controlled, inert atmosphere that eliminates weather-related variations affecting coating uniformity. This allows for consistent, even coating application that cannot be achieved in outdoor conditions, resolving the contradiction between onsite deployability and coating quality consistency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces coating material wastage, transportation costs, and equipment complexity, while ensuring uniform coating quality and efficient installation, resulting in a more cost-effective and environmentally friendly secondary containment system.
Implementation Method 1
a computer controlled robotic sprayer to apply a liquid impermeable coating, such as polyurea, onto an upper surface of the substrate piece
Implementation Method 2
measurement of dry coating thickness with magnetic gauges
Data Source
AI summary
A method of manufacturing a plurality of secondary containment panels and assembling and installing the panels in a secondary containment system of an above-ground liquid storage tank or other retention facility includes forming a plurality of flexible substrate pieces. A liquid impermeable coating is applied to the upper surface of each piece such that an edge segment of the piece remains uncoated. The coating is applied to the substrate piece in an indoor enclosure using a computer controlled robotic sprayer that applies a uniform coating. Metal plates are embedded in the floor used for quality control testing of the coating thickness using magnetic gauges. At least a pair of the pieces are juxtaposed relative to one another such that a first one of the pieces overlaps the uncoated segment of the second piece to form a seam.