Case Study:

Situation:

An Indiana wastewater treatment plant needed to expand its ferrous chloride containment area, adding approximately 2,000 square feet of secondary containment space. The newly constructed concrete surfaces required a protective lining capable of withstanding the aggressive chemical conditions associated with ferrous chloride storage. 

SprayWall had previously been installed at the facility in 2011. As part of the expansion, the existing lining remained in place, with new SprayWall lining applied to the additional containment areas to extend the same long-term protective system throughout the expanded facility. 

Solution:

Conco Spray Solutions, a Sprayroq Certified Partner, performed the protective lining installation using SprayWall structural polyurethane lining. 

Surface preparation began with scarifying the new concrete, followed by the use of fast-setting mortar to round corners and fill bugholes. These steps prepared the surfaces for a consistent lining application. 

The team then applied SprayWall at the specified thickness of 276 mils (7 mm), creating a chemical-resistant protective barrier across the new containment surfaces. 

Results:

Completed in June 2025, the project provided the expanded secondary containment area with a SprayWall lining to withstand exposure to ferrous chloride. 

The original SprayWall lining continued to perform as intended, the goal of the project was to extend that protection into the newly constructed containment areas, creating a continuous protective lining system throughout the expanded facility. 

Conclusion:

This project demonstrates how SprayWall can rehabilitate challenging wastewater treatment infrastructure, providing chemical-resistant protection for newly constructed containment areas while complementing an existing lining system.