- The Company
- Certified Partners (SCP)
- Product and Performance
- Environmental Compliance
- Quality Assurance
Sprayroq created its first polyurethane in 1990 in Jacksonville, Florida. Since that time, Sprayroq products have been applied to over 150,000 structures throughout North America, Europe and Asia.
No, Sprayroq is a manufacturer of a line of advanced polyurethane products used in the water, wastewater and industrial coatings markets. Our products are applied by highly trained Sprayroq Certified Partner applicators. A listing of the current Sprayroq Certified Partners is available on the Sprayroq website.
At this point, no, all applicators (Sprayroq Certified Partners) of the Sprayroq product line are exceptionally well trained by our Operations Staff in Birmingham for one full week and for another week in the field about a month after initial training. There is a specific process to using spray applied polymer technology that involves a thorough understanding of water and wastewater system operations, confined space training, surface preparation, equipment maintenance, basic chemistry and spray technique. This is all taught at the SCP training classes.
Each applicator is then certified by the Director of Operations as a Sprayroq Certified Applicator who receives both a certificate and laminated wallet card signed by the President of Sprayroq. Ask your local SCP for verification of the applicators training.
The training begins by your new crew spending a week in Birmingham for intensely-focused training on Sprayroq equipment, products and application techniques. That week consists on several key areas of concentration that will create successful finished projects. These areas of learning include:
- Safety (Note: if Confined Space training is required, Sprayroq can arrange that for you at your facility.)
- Basic chemistry for the applicator
- Equipment setup and maintenance
- Surface preparation
- Spray technique
NOTE: Confined space training is required prior to attending the SCP applicator training class
About 3-4 weeks after the Birmingham training, our Sprayroq Trainer will visit with you in the field to fine tune your training by co-supervising any jobs or demo projects that your company has arranged.
If your company is looking to move to the next level of growth and you have a strong familiarity with the water and wastewater infrastructure issues in your area, you may be positioned to consider Sprayroq products as your way of increasing your company revenue stream and profitability while providing a long term infrastructure rehabilitation solution for your community. Contact Sprayroq at 800-634-0504 or contact us through our Internet site. Tell us a bit about yourself and your plans for growth.
One thing, we do limit the number of contractors in a given area, so first check to see if there is an SCP in your area.
The SCP understands that the best way for you to evaluate their products and services is to provide a sampling of the work. Just call your local SCP or Sprayroq to arrange such a demonstration project.
Refer to the Sprayroq website for the latest listing of North American and other international SCP’s serving your area. Locate a Partner Link . You may also call Sprayroq directly ay 800-634-0504 for a referral to your local SCP.
“SCP” stands for Sprayroq Certified Partner. These are highly trained contractors who worked in specific geographic areas. Each SCP has Sprayroq trained applicators who understand the need for quality throughout the rehabilitation or corrosion preventive coating process. Only SCP’s may apply Sprayroq Products.
No. Most common epoxy resins are produced from a reaction between epichlorohydrin and bisphenol-A. SprayWall is polyurethane that is produced from a reaction between a polyalcohols and an Isocyanate.
Polyurethanes cure much faster than epoxies and therefore can be applied much thicker in one application. Typically, an epoxy must cure for 6-10 hours. Sprayroq’s polyurethane products begin curing in about 10 seconds. They reach a tack-free state within 2 minutes and full cure through within 4-6 hours.
SprayWall has the ability to return a structure to water service 30-60 minutes after application, based upon the thickness of the application.
No. Polyurethanes are generally the reaction product of polyalcohols and Isocyanate. Polyureas result from reacting polyetheramines and Isocyanates and usually require a primer. Sprayroq products normally do not require primers.
Surface prep is the key to any successful polymer application. Generally, power washing with 3,000 psi water pressure will address most cleaning needs. Sometimes, higher water pressure and/or the use of a biodegradable cleaner may be needed for more difficult cleaning jobs.
After the power washing is complete, inspect the structure for infiltration. If you discover even a small degree of infiltration, use a very good chemical grout system such as Quadex and/or Strong Seal to seal off the infiltration.
If point repairs are necessary, a calcium aluminate based cement or strong Portland cement should be used to rebuild the profile of the structure. Use the cement to replace any missing mortar between bricks or to fill in voids from poured or precast structures.
Once the cement has dried by ambient temperatures or by an accelerated process, you may begin the spray applied rehabilitation process.
Caution: Be sure that your surface area is both clean and dry. This is true for any polymer you may use.
One of the measures of SprayWall is known as “flexural modulus”. That is the point in which the sample of material yields under the pressure of a testing device. The rating, measure in pounds per square inch, tells the engineer what the strength of the product may be. Sprayroq uses the most conservative numbers to represent flexural modulus. That number is 735,000 psi.
Let’s compare that to a well know product called cured in place pipe, CIPP. Most resin filled fiber liners have a flex modulus rating of 360,000 psi to 400,000 psi, which is a very strong product. Some other newer materials will go higher, but compared to the most common felt liner, SprayWall is tested out at nearly twice that of CIPP with the same 50 year design life that accompanies CIPP products.
The curing process of Sprayroq products begins in about 8-10 seconds with what we call “gel time”. A thin skin is formed on top of the freshly sprayed surface which quickly continues to solidify throughout the application. In about 2 minutes, a “tack free condition exists where the product is able to support the weight of the applicator safely while the spray application continues.
Within 30 minutes, the initial cure is complete and the structure is capable of accepting flow* while the complete curing process continues for the next 72 hours.
The majority of structures may be returned to active service within 30-60 minutes after the application*. Thicker applications may be returned to service even sooner. This is due to the accelerated curing that takes place in a larger mass of spray applied material.
* Potable applications require a 72-hour cure time in order to meet WQA standards
Indeed! This product, in a structural finish, has a 50 year design protocol. Other technologies may not have that same service life expectancy. When municipal funds are being used for rehabilitating vital infrastructure, the taxpayer is entitled to the longest lasting, comprehensive solution available. With its 50 year design life, SprayWall will continue working 24/7 while other technologies may have to be reapplied anywhere for 3 to 15 times on that same structure over a 50 year time span.
The natural color of SprayWall has a golden tone to the finished product, thus we use the phrase, “the Gold Standard” as part of our marketing initiative. As this is part of our identity, we will not change the color of our core products.
We do have the ability to modify the colors of our polyurea products to virtually any color. The standard colors are either black or blue, but we can color the polyurea to meet your specific job requirements.
Will that take multiple mobilizations and extra bypassing?
One! The beauty of our products is that we can build up to about 500 mils (one-half inch) or about 13 millimeters in a single application. This unique feature of our product allows our SCP’s to keep their cost in line by minimizing mobilizations to only one trip, reducing expensive bypassing requirements and returning the structure to service sooner than other technologies.
Bone dry! But, our SCP’s understand the nature of drying out a structure by the effective use of grouts and special techniques to assure that the structure is in perfect condition for a spray applied application of Sprayroq products.
Hydrogen Sulfide is converted to Sulfuric Acid in sewer systems. SprayWall is resistant to the corrosive effects of Sulfuric Acid. However, in its Hydrogen Sulfide state, Spraywall’s polyurethane formulation controls the destructive nature of the gas.
The key word in any structure is to start with a clean and DRY surface. This applies to any polymer. In other words, the quality of the surface prep should reflect the quality of your finished structure.
The next issue, and equally critical, is to have a dedicated, manufacturer trained applicator team who have the ability to address the wide area of conditions they will encounter when using any polymer product for rehabilitation linings or corrosion coatings.
With Sprayroq’s quick curing polyurethanes, you can return a structure back to active water service in 30-60 minutes. If there is a thicker mass of material sprayed, you may return it to service even sooner due to the accelerated curing process that accompanies the heat of that thicker mass of material.
All Sprayroq products are quick curing polyurethanes, Polyureas or hybrids; with one exception, SR6100 is a trowelable, high strength epoxy used for spot repairs or for coating structures where our SCP’s spray rigs cannot access.
SprayWall is a structural, spray applied polyurethane with a flexural modulus of 735,000 psi and 4% elongation. This unusual combination of performance factors is part of what helps SprayWall achieve a 50 year design protocol. As well, SprayWall is NSF certified for use in potable water applications. It is excellent for use in infiltration control, high hydrostatic loading and structural reinstatement of deteriorated water structures.
SprayShield is polyurethane as well, but is highly elastomeric with excellent tear strength. It is designed to use in applications where thermal cycling and geological events are commonplace. SprayShield I has the same corrosion resistant qualities as SprayWall and is NSF certified for use in potable water applications as well.
If our products are applied to a wet surface, they will react violently to contact with water. This “hydrophobic” condition affects different polymers in different ways. The reason that foaming and blistering is a good thing is that the applicator realizes within a second or two that they have not dried the substrate surface properly. If this condition occurs, they can stop, address the moisture issue and re-spray within the 15 minute time window to allow the new spray and existing application to meld together.
Other polymers, like epoxies, may not react at all when they come in contact with a wet surface. This may also diminish the quality of the bond and lead to problems in the years ahead.
To address hydrostatic load, we use the modified Timoshenko Equation to determine the lining thickness of the SprayWall throughout the structure. This is an equation similar to that used by CIPP installers to determine the thickness of the tube they are installing in your wastewater collection and storm system pipes.
Although Sprayroq requires the prospective SCP to be confined space trained by a qualified trainer, we do not perform that service. We are fortunate to be aligned with companies that can perform that training for our SCP and prospects. The fee for training is absorbed by the applicator.
Yes! Although our products are environmentally friendly, they can be hazardous to people in the immediate area during a spray application. During our Sprayroq Boot Camp, we teach applicators what is the proper protective equipment that must be used during a spray application. This equipment includes a full air mask supplied by fresh air, not organic cartridge filters. The applicator must use a Tyvek suit, safe rubberized gloves and shoe covers.
The safety person (the person standing above the open structure relaying messages and safeguarding the applicator) must also be equipped with fresh air or organic cartridge filter. The Operator in the truck, depending on the distance from the structure, may require an organic cartridge filter mask. Most of the time, this person is far enough away from the spray area.
Yes. All Sprayroq products are VOC free (Volatile Organic Compound) without solvents or other harmful components that may damage the environment.
Green Products are materials from Renewable Sources are defined as products made from raw materials that are capable of being replaced by natural ecological cycles or sound management practices. Renewable sources include, but are not limited to soy, corn or hemp oils. As applied to the polymer market, when substituting 20% or more of the petroleum based materials, a Green Product has been created.
This Standard is intended to cover specific materials or products that come into contact with: drinking water, drinking water treatment chemicals, or both. The focus of the Standard is evaluation of contaminants or impurities imparted indirectly to drinking water. The products and materials covered include, but are not limited to, process media (carbon, sand, etc.), protective materials (coatings, linings, liners, etc.), joining and sealing materials (solvent cements, welding materials, gaskets, etc.), pipes and related products (pipes, tanks, fittings, etc.), mechanical devices used in treatment/transmission/distribution systems (valves, chlorinators, separation membranes, etc.), and mechanical plumbing devices (faucets, endpoint control valves, etc.). Point-of-use and point-of-entry drinking water treatment devices are not covered by the scope of this Standard.
No not all of our products are certified for use in potable water applications. Currently, our core product, SprayWall, and our elastomeric product, SprayShield Green I, are certified. The two products that Sprayroq has certified will address most if not all common coating applications in potable water applications.
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Unfortunately, Sprayroq products cannot coat the inside of small diameter pipes that are in service. Due to the density of our product, we have not found a reliable means of delivering the product to the inside of the pipes in the ground. As well, the need to apply the polyurethane on a dry substrate is difficult to attain in an active pipe.
Other technologies such as cured in place pipe, pipe bursting, slip lining and fold and form technologies are much more cost effective and practical in this environment.
Sprayroq can be used in man-entry applications and can be very competitive and practical for those applications. Where there are unusual shapes and difficult bends to negotiate underground, our SCP’s can effectively rehabilitate your existing oval, egg shaped, arched, rectangular and even round structures quickly, efficiently and cost effectively.
(i.e. manholes, lift stations, wet wells, etc)?
Absolutely! Due to urban sprawl and the rebirth of “grayfields”, more and more communities and engineers are taking the extra step of coating new wastewater and water structures to extend the life of the service to the community. As infiltration and the effect of corrosive gases are two primary cause of deterioration in a collection system, the addition of a corrosion barrier to a new structure will ensure a longer life to the system and a better ROI for the taxpayer.
You must stop any infiltration using appropriate water-stopping material before applying Spraywall. Once that has been accomplished, finish preparing the structure for spraying. Once you spray the substrate with Sprayroq’s SprayWall structural product, the polyurethane will bond to the concrete, steel or masonry, sealing of the infiltration.
Yes, you could, but it probably isn’t practical or cost effective. SprayWall and SprayShield were formulated to work in a water and wastewater environment. The use of the product for other sealing and corrosion coatings may not be the best answer. Check with your local SCP or Sprayroq to see if your application may be right for this product line.
No, Sprayroq products have a tenacious bonding ability to not only concrete, but steel, aluminum, masonry materials and other substrates that may be used in our water and wastewater systems. SprayWall and SprayShield will not bond to polyethylene.
Some of the applications for Sprayroq products include coatings or linings of the following structures¦
- Manholes (Water and utility)
- Junction boxes
- Lift stations
- Storm sewers
- Wet wells
- Grit chambers
- Retention ponds
- Secondary containment fields
- Water tanks
- Corrugated pipes
- Plus many other applications in the water industry and other industrial infrastructure rehabilitation and corrosion coating applications.
Yes, all batches are tested to product specifications such as viscosity and reaction and cure rates. Testing occurs at both the production plant and lab which are co-located with our home office in Irondale, Alabama. Any discrepancies would initiate an investigation of that particular batch.
If the 55 gallon drums remain sealed, the expected shelf life of the products is one year. If the drum has been opened and may not be used for a time, be sure to reseal the drum tightly to protect the product from moisture and top off the void in the drum with nitrogen if possible.
The warranty for the Sprayroq product line is three years from the date of application. SprayWall warrants that its material is free of defects at the time of application. Should any product be found to be defective, the product will be replaced by SprayWall or the money will be refunded to the SCP.
Sprayroq will not assume the warranty for workmanship. That is the domain of the contractor and is an agreement made between the owner and SCP for addressing the quality and integrity of the installation.
Yes, in fact, if you visit our website, you will find a sample specification for corrosion coatings and structural rehabilitation under our Specifications section of the website.
Sprayroq has included on this site a number of projects that have been completed and documented by our SCP base. These case studies present an overview of the project, some photos and the contact information of the SCP who completed the project. This is for those who have similar projects to contact the contractor who successfully completed a similar project.
Dynamic Mechanical Testing is a procedure for predicting the life of the physical properties of a material.
A procedure for measuring the adhesion to a substrate.