untitled BRITISH STANDARD BS EN 14879 5 2007 Organic coating systems and linings for protection of industrial apparatus and plants against corrosion caused by aggressive media — Part 5 Linings on conc[.]
Surface protection types and systems
Surface protection is typically implemented as a lining, as outlined in section 4.1.2 and Clause 5, or as a coating according to EN 14879-3 Additionally, it can be applied as a composite coating or lining system, as specified in prEN 14879-6, which integrates a chemically resistant sealing coat with a durable wearing layer.
Linings based on organic binders, such as a) Bonded linings
Bonded linings consist of pre-fabricated sheets adhered to the substrate with a comprehensive adhesive application These sheets are subsequently joined either through adhesive or welding methods In contrast, mechanically fixed linings utilize different fastening techniques for attachment.
Thermoplastic linings, such as sheets, slabs, or pre-formed pieces, are securely attached to concrete substrates using systematically arranged fasteners on their underside These lining units are subsequently joined together through a welding process.
Linings can be applied during the construction of concrete members or after completion, where they are affixed to a layer of facing concrete Additionally, loose linings made of sheeting material are also an option.
Pre-fabricated linings that are laid loosely on the substrate, jointed and then fixed to the walls by means of metal beads, for example
Sheets are typically covered with gravel or screed, or safeguarded from sunlight, warping, and mechanical damage through a masonry facing Additionally, loose linings made of pre-formed pieces or lining units are utilized for added protection.
Linings made of pre-formed pieces laid in the concrete member and then fixed or welded at the top edge, if necessary.
Selection criteria
Understanding the stress that a protective lining will face is essential for defining its requirements This standard highlights the most pertinent types of stress, as outlined in sections 4.2.2 to 4.2.8 Additionally, various grades are utilized to indicate different levels of stress when necessary.
Aggressive substances, which can be found as solids or liquids, pose a significant threat to concrete, particularly when in liquid form such as aqueous solutions or condensates These pollutants may exist in pure form or as mixtures and can attack concrete at different intervals.
Substances should be identified using Geneva nomenclature, IUPAC nomenclature, or CAS numbers, and may also be referred to by established trivial names Concentrations and any modifications must be expressed as a percentage by mass or volume, or in units such as g/l, g/kg, or mol/l Additionally, the pH value must be provided for aqueous solutions.
All constituents, including traces and impurities, shall be named, even if they do not attack concrete Successive exposure shall be represented accordingly
Table 1 lists chemicals which are commonly used, having the properties mentioned above
1) International Union of Pure and Applied Chemistry
Table 1 — Classification of frequently (commonly) used chemicals
Inorganic, non-oxidizing acids HCl
Hydrochloric acid Sulphuric acid, up to 70 % Phosphoric acid
Nitric acid Sulphuric acid, over 70 % Chromic acid
Chloric acid Inorganic acids, dissolving SiO2 HF
Hydrofluoric acid Hexafluorosilicic acid (containing HF) Tetrafluoroboric acid (containing HF)
Sodium chloride Iron (II) sulphate Sodium carbonate
Sodium hydroxide Potassium hydroxide Calcium oxide Calcium hydroxide Ammonia solution (Ammonium hydroxide solution)
Oxidizing bases NaOCl Sodium hypochlorite
Formic acid Acetic acid Chloroacetic acid Oxalic acid Lactic acid Aliphatic hydrocarbons C6H14
Benzene Toluene Xylene Alcohols CH3OH
Methanol Ethanol Butanol Ethanediol Aldehydes, Ketones, esters CH2O
Formaldehyde Acetone Methyl ethyl ketone (2.butanone) Ethyl acetate
Aliphatic halogenated hydrocarbons CH2Cl2
Dichloromethane Trichloroethylene Trichlorotrifluoroethane Aromatic Halogenated hydrocarbons C6H5Cl
Chlorobenzene Chlorobenzotrifluoride Aliphatic amines CH3NH2
Methylamine Triethylamine Ethylene diamine Aromatic amines C6H5NH2
Phenol Cresol Fats, oils Vegetable and animal fats and oils NOTE The grades 0 to 2 and 4 are normally not applicable for linings according to this standard
4.2.3 Type and frequency of fluid loading
The protective or sealing function of a surface protection system is determined by the type and frequency of fluid loads it encounters The exposure levels should be categorized accordingly.
Grade 0: no exposure to fluids
Grade 1: sporadic exposure to droplets of fluid (e.g laboratory floors, floors in small units, walls)
Grade 2: frequent, short-term exposure to splashes of fluid, where the surfaces are regularly flushed (e.g floors of closed production plants)
Grade 3: exceptional and limited exposure to fluids during operations (e.g due to plant failure) in, for example, collecting basins
Grade 4: constant or frequent exposure to a film of fluid, due to wetness, condensation, puddles, trickles and the like (e.g floors in production plants, electroplating plants or pumping stations)
Grade 5: operational exposure to a constant flow of fluid involving no significant hydrostatic pressure (e.g open gutters, trenches and their pump sumps, closed trenches and pipes)
Grade 6: constant exposure of containers to fluid contents for unlimited periods (e.g vessels, pits)
Temperature influences the effectiveness of a surface protection system in the following ways a) Aggressiveness of medium
Elevated temperatures enhance the aggressiveness of the medium by increasing chemical reaction rates and diffusion, as well as promoting the accumulation of volatile substances in the headspace Additionally, thermal stress plays a significant role in this process.
Deviations from the installation temperature can lead to thermal stress between the substrate and the surface protection system, potentially resulting in issues such as peeling and cracks This stress may arise from direct exposure to hot or cold media, as well as from radiant heat and extreme ambient temperatures.
The maximum thermal load shall be stated in °C
Temperature changes can occur at the protective surface due to fluid loads of grades 3 to 5, as outlined in section 4.2.3, which involves variations in medium temperatures Additionally, surfaces that are constantly heated or cooled may experience temperature fluctuations due to operational events like start-up and shutdown Cleaning operations can also induce temperature changes, potentially leading to thermal shock Furthermore, process-related temperature variations may arise in the medium under loading conditions corresponding to grade 6, as mentioned in section 4.2.3.
Temperature changes due to climatic influences are dealt with in 4.2.7
The source, degree, speed and frequency of temperature changes shall be taken into consideration when assessing their effect
The following grades serve in assessing the effects of temperature changes, whereby details of the frequency and the duration of temperature changes are to be given for grades 1 to 4
Grade 1: infrequent temperature changes of not more than 50 K;
Grade 2: infrequent temperature changes of more than 50 K;
Grade 3: frequent temperature changes of not more than 50 K;
Grade 4: frequent temperature changes of more than 50 K;
Grade 5: temperature changes involving thermal shock (assessment not possible with this standard)
The performance of a surface protection system can be compromised by mechanical loads or hydrostatic pressure encountered during operation or assembly To evaluate these loads, the following grading system is applied: Grade 0 indicates no loads or hydrostatic pressure of up to 0.05 bar.
Grade 1: loads up to 0,2 N/mm 2 (e.g pedestrian traffic, light transport, static loading);
Grade 2: loads up to 1 N/mm 2 (e.g vehicles with pneumatic tires, static loading);
Grade 3: loads over 1 N/mm 2 , for example a) loads of 1 N/mm 2 to 7 N/mm 2 (e.g vehicles with Vulkollan wheels, static loading) and b) loads over 7 N/mm 2 (e.g vehicles with polyamide wheels, static loading);
Grade 4: impact loads, such as those resulting from setting down sharp-edged objects (e.g barrels), and from scraping (e.g shovel loaders);
Grade 5: hydrostatic pressure from 0,05 bar to 0,5 bar;
Grade 6: hydrostatic pressure greater than 0,5 bar
NOTE The grades 2 to 4 are normally not applicable for linings without additional protection according to this standard
Climatic influences may affect the durability of a surface protection system, and shall be graded as follows
Grade 0: no climatic influences: the component is located inside a building and is not exposed to climatic influences
Grade 1: limited climatic influences: a roof protects the component, which is exposed to limited climatic influences
Grade 2: full climatic influences: the component is located outside, and is fully exposed to climatic influences
Special applications may necessitate additional requirements not fully addressed by this standard, including aspects related to water protection, explosion and fire safety, decontamination, and health and safety, particularly concerning food and drinking water Furthermore, considerations for non-slip surfaces and smoothness are also essential.
Load profile
The loads described in 4.2.2 to 4.2.8 shall be recorded, together with the grades selected, using the form reproduced in Annex A
Tables B.1 to B.5 list frequently occurring load profiles and suitable surface protection systems
Lining materials
Lining materials, along with the adhesives and jointing materials, must be durable enough to endure the chemical, mechanical, and thermal stresses outlined in the specified load profile sections 4.2.3 to 4.2.8 and Annex B.
Specific properties (e.g compatibility between chemicals and the lining, resistance to mould and bacterial growth, resistance to ultraviolet or radioactive radiation, or electrostatic dissipation) may be required for special applications.
Lining materials manufacturer
Manufacturers of lining materials shall have suitable, functional manufacturing equipment and qualified personnel
Lining materials shall be accompanied upon delivery by an inspection certificate 3.1 according to EN 10204.
Applicator
The applicator shall have suitable equipment and qualified personnel; this will ensure that the lining is properly applied in accordance with this standard
Materials for bonded linings
Soft rubber linings are made from single or double-ply sheets of self-vulcanizing or partially to fully vulcanized soft rubber These lining systems can be applied in multiple layers for enhanced performance.
Table 2 lists commonly used rubbers and the maximum temperatures for which they are suitable
Table 2 — Recommended maximum operating temperatures for soft rubbers
Symbol Rubber type Maximum temperature in °C
NR Isoprene rubber (Natural rubber) + 80
IIR Isobutene-isoprene rubber (Butyl rubber) + 100
BIIR Bromo-isobutene-isoprene rubber
CIIR Chloro-isobutene-isoprene rubber
NBR Acrylonitrile-butadiene rubber (nitrile rubber) + 80
The operating temperatures for which the rubbers are suitable will depend on the type and duration of loading Table 3 specifies requirements for soft rubber sheeting
Table 3 — Requirements for soft rubber sheeting
Elongation at break, as a percentage
EN ISO 868) (testing as in ISO 37)
IIR, BIIR, CIIR, CSM NBR
Partially vulcanised single-ply sheets a
CIIR and BIIR 2 to 5 1,10 to 1,30 50 to 65 ≥ 3 ≥ 300
Self-vulcanising single-ply sheets a
≥ 300 a Values refer to the rubber in its completely vulcanised state
Thermoplastics sheets shall be of polyisobutylene (PIB) or plasticised poly(vinyl chloride) (PVC-P)
The operating temperatures for which these thermoplastics are suitable are given in Table 4
The operating temperatures for which the thermoplastics are suitable will depend on the type and duration of loading
Table 4 — Recommended maximum operating temperatures for thermoplastics
PVC-P Plasticised poly(vinyl chloride) + 65
Table 5 contains general requirements for thermoplastic sheeting
Table 5 — Requirements for thermoplastics sheeting used in process plant
Tear strength, in N/mm 2 Elongation at break, as a percentage
EN ISO 2286) (testing as in EN ISO 6721-2)
Materials for mechanically fixed linings
Table 6 lists thermoplastics commonly used for mechanically fixed linings and the temperature ranges for which they are suitable
Table 6 — Recommended operating temperature ranges for thermoplastics used in mechanically fixed linings
Symbol Type of thermoplastic Temperature range, in °C PVC-U Non-plasticised poly(vinyl chloride) – 5 to + 60 PE-HD High density polyethylene – 30 to + 80
PVDF Poly(vinylidene fluoride) – 30 to + 140
The operating temperature ranges for which the thermoplastics are suitable will depend on the type and duration of loading
Table 7 specifies requirements for materials used in mechanically fixed linings
Table 7 — Requirements for thermoplastics used in mechanically fixed linings
Property Unit Testing as in PVC-U PE-HD
Nominal thickness mm EN ISO 2286 ≥ 3 3 to 10 3 to 10 ≥ 3
Density g/cm 3 EN ISO 1183-1 Formulation- dependent
As specified for sheet groups 1 and 2 in EN ISO 14632
Melt-flow rate g/(10 min) EN ISO 1133 — 190/5:
Tensile strength at break (for PVC-U, tear strength)
Notched bar impact strength kJ/m 2 EN ISO 179 ≥ 2 20
Dimensional change after exposure to heat
To ensure proper installation of the lining, it is essential that the fastener attachment is robust and devoid of residual stresses Additionally, the configuration of the attachments to the concrete substrate must guarantee a secure fixation of the lining without inducing stress.
Materials for loose linings
The materials described in 6.1 to 6.2 may be used for loose linings, depending on the load profile and application Polyethylene copolymers and multi-layered sheeting may also be used
Requirements shall be taken from Table 3, 5, 7 or 8, depending on the material selected
Table 8 — Requirements for polyethylene sheeting used as loose lining
Nominal thickness, in mm Tear strength, in N/mm 2 Elongation at break, as a percentage Type of material Relevant standard
EN ISO 2286) (testing as in EN ISO 6721-2)
Pre-formed pieces shall be of the materials specified in 6.2 and shall meet the requirements of Table 7
Bonded linings
The preparation of the concrete surface must adhere to the standards set by EN 14879-1 Any pores, cavities, or uneven areas should be filled or smoothed using either a polymer modified cement or a solvent-free epoxy resin mortar.
To conduct spark testing for verifying the continuity of the lining, it is essential to completely cover the concrete surface with a conductive resin If a non-conductive material is utilized for surface leveling, an electrically conductive primer must be applied to facilitate the spark testing process.
The substrate temperature must be maintained at a minimum of +5 °C and at least 3 °C above the dew point during the lining process It is essential to implement appropriate measures to ensure that the substrate temperature does not drop below these specified values.
Normally, a primer is to be applied to the substrate to improve adhesion The primer shall be fully dried before the adhesive is applied
To ensure adhesion over the entire surface, the adhesive should be applied to the substrate and the underside of the rubber sheet simultaneously
Once the adhesive has dried according to its specific requirements, use a specialized roller or suitable tool to apply the rubber sheet to the substrate, ensuring complete adhesion across the entire surface.
Jointing shall be carried out according to the manufacturer's instructions, taking the requirements of
The preparation of the concrete surface must adhere to EN 14879-1 standards Any pores, cavities, or uneven patches should be filled or smoothed using polymer modified cement or solvent-free epoxy resin mortar.
After the substrate is completely covered with filler, it is typically made electrically conductive to allow for spark testing of continuity in the lining If a non-conductive material is used for surface leveling, an electrically conductive primer must be applied to enable spark testing.
Normally, a suitable primer is to be applied to the substrate to improve adhesion The primer shall be fully dried before the adhesive is applied
For optimal adhesion, a solvent-based contact adhesive must be applied to both the substrate and the underside of the thermoplastic sheet at the same time It is essential to choose an adhesive that is compatible with the specific thermoplastic material being used.
Once the adhesive has dried, apply the thermoplastic sheet to the substrate with a specialized roller or suitable tool, ensuring complete adhesion across the entire surface.
A hot-melt bitumen adhesive may be used where thermoplastics that are compatible with bitumen are laid on floor surfaces
Under certain circumstances, some types of thermoplastic sheeting may be laid on a special emulsion adhesive
Depending on the type of sheeting used for the lining, the following welding methods may be used for jointing (the manufacturer's instructions shall be observed):
Hot gas welding (as in DVS 2225-1);
Heated wedge welding (as in DVS 2225-1);
Diffusion bonding (a solvent welding procedure; as in DVS 2225-1)
The first two methods listed shall be performed by persons qualified in accordance with EN 13067 and carried out according to national guidelines, e g DVS 2225-1.
Mechanically fixed linings
When addressing cracks in the substrate wider than specified in EN 14879-1, it is essential to ensure that any permanent deformation does not exceed 3% of the anchor spacing to avoid stress cracking in the lining Additionally, if weld seams are present in the affected area, the allowable deformation is further limited to 2% of the anchor spacing, accounting for the width of the weld seam.
Mechanically fixed linings can tolerate moisture from the rear side, but if hydrostatic pressure occurs, such as groundwater seeping through concrete, it is essential to demonstrate long-term anchoring strength and resistance to bulging between anchors This can be achieved by conducting a test in accordance with section 10.2.6.2.2, while considering the operating conditions.
Lining units (panels, pre-formed pieces) of PVC, PP and PVDF shall not be applied at an ambient temperature lower than + 5 °C
The lining can be installed as permanent formwork during concrete construction or applied afterward using facing concrete or mortar It is essential for the lining to fit tightly When selecting concrete aggregate, the geometry and arrangement of fasteners must be considered Unless specified otherwise by the lining material manufacturer, the maximum particle size should not exceed half the shortest distance between fasteners.
Lining units shall be clamped firmly to the formwork
The number of penetrations (e.g for spacers) shall be kept to a minimum and the use of nails, bolts, etc is to be avoided
Temperature-induced movements (expansion and compression) shall be accommodated by using suitable profiles so that the lining lies flat and stress-free on the formwork
The lining must be installed on a cementitious screed that is a minimum of 50 mm thick and classified as CT 30 or higher according to EN 13813 standards, or alternatively, grout should be poured underneath.
When applying a lining subjected to hydrostatic pressure, it is crucial to do so while the concrete is still fresh If the lining is installed after the concrete member has been constructed, a permanent bond between the concrete substrate and the screed must be established.
One of the following welding procedures may be used, depending on the form of the joints to be welded:
Hot gas welding (as in DVS 2207-3);
Heated tool welding (as in DVS 2207-1);
Extrusion welding (as in DVS 2207-4)
Welds that will be subjected to a continuity test by spark testing shall be backed by an electrically conductive material
Welding imperfections are to be avoided
In addition, national guidelines (e g DVS 2203 series) apply to the testing of welded joints in thermoplastic materials
Welding shall not be carried out until the concrete is sufficiently dry; otherwise, the hot gases used for welding may produce steam in joints
During welding, it is essential to implement protective measures against environmental factors such as temperature fluctuations from wind or sun, as well as the presence of dust or rain Special precautions must be taken if the ambient and substrate temperatures drop below +10 °C.
Under no circumstances shall condensation be allowed in the welding area
Welding shall be carried out by qualified welders approved in accordance with national guidelines, e g DVS 2212-1 or DVS 2212-2.
Loose linings
7.3.1 Special requirements regarding operating conditions
To minimise stresses in the lining, the following operating conditions shall be taken into consideration:
fluctuations in the operating temperature;
hydraulic loads (e.g changes in the filling level);
abrasion caused by the charge (e.g in mixing vessels);
other mechanical loads (e.g vehicle loads)
If the lining will be subjected to hydrostatic pressure on the reverse side, it shall be proven that no risk of uplifting or buckling exists
For substrates with cracks wider than those outlined in EN 14879-1, it may be essential to implement crack-bridging solutions The linings detailed in this standard can effectively bridge cracks measuring up to 1.5 mm in width.
To protect the lining from damage, ensure the substrate is smooth and devoid of burrs or offsets It may be essential to use a screed or protective mat on the substrate, as the back of the lining could be susceptible to moisture exposure.
Sheets shall be laid on the concrete surface, jointed, tested and, if necessary, provided with an additional layer (e.g a screed) as protection against mechanical damage and sunlight
When applying pre-formed pieces to concrete members, it is crucial to ensure that the walls of these pieces are tightly sealed against the concrete surface This prevents hydrostatic pressure from the charge from causing excessive stress on the lining material.
Depending on the type of material used, jointing shall be carried out in 7.1.2.4 or 7.2.4 (for thermoplastics)
EXAMPLES a) The designation of a soft rubber lining (B) of a total thickness of 5 mm, based on single layer (1) natural rubber (NR) shall read:
Soft rubber lining EN 14879-5 B 5 1 NR
Type of lining (B bonded, A anchored, L loose lining)
Total thickness, to the nearest mm
Material b) The designation of a thermoplastic lining (A) of a total thickness of 5 mm, based on single layer (1) high density polyethylene (PE-HD) shall read:
Thermoplastic lining EN 14879-5 A 5 1 PE-HD
Type of lining (B bonded, A anchored, L loose lining)
Total thickness, to the nearest mm
General
The testing type and scope, along with the necessary documentation, will be established through case-by-case agreements that outline the requirements, any deviations from those requirements, the specific tests to be conducted, the required test equipment, the testing schedule, and the ambient conditions.
Suitability testing
Suitability testing shall be carried out according to Clause 10.
Checking the substrate
The lining applicator shall check the substrate to ensure that it has been properly prepared in accordance with Clause 7 and that it meets the requirements of EN 14879-1.
Receiving of lining materials
Upon receipt, it is essential to verify that the marking of lining materials and the dimensions of lining units comply with the order details, delivery documents, and the inspection certificate specified in section 5.2.
Mechanical testing of lining units may be performed in accordance with the test standards listed in Tables 3, 5,
In-process testing of lining
It is essential to ensure that the necessary ambient conditions are upheld from the beginning of substrate preparation through to the end of the lining process, in accordance with the guidelines outlined in Clause 7.
It shall be ensured that the lining units (sheets, pre-formed pieces) are properly applied (e.g by checking the application plan and assembly instructions)
9.5.3 Jointing, bonding and anchoring linings
It shall be ensured that the manufacturer's instructions regarding jointing, application of adhesives and fixing of anchors are observed, taking the specifications of Clause 7 into consideration.
Checking the completed lining
The lining shall be deemed ready for use in accordance with the 'load profile' if no flaws are discovered during the following tests
The lining shall be visually examined for flaws such as cracks, blisters, voids, inclusions of foreign material and any damage to the lining surface or joints
Spark testing is typically used to assess the continuity of non-conductive linings and welds on conductive substrates The voltage for spark testing and the precision of measurements must be mutually agreed upon Additionally, EN 14879-4 provides guidelines for spark testing by analogy.
It is not possible to perform spark testing on a conductive or dissipative lining, in which case another form of continuity testing shall be agreed upon.
Tests during the application works
It shall be ensured that welding and bonding are properly carried out The scope of the inspection and criteria for compliance shall be agreed upon before construction begins.
Inspection report
All tests and inspections must be recorded in distinct reports or, if agreed upon, in the construction log These reports are classified as construction documents and should be retained on file Sample forms for inspection reports and schedules can be found in Annex C and H, respectively.
Requirements
The requirements for linings encompass the entire scope of application specified in Clause 4 However, in specific applications, only certain criteria must be fulfilled based on the loading conditions of the component being protected Annex D provides a summary of the essential certifications of suitability.
Requirements to which no verification is assigned for a certain surface protection system or a certain loading grade are omitted for this application
Independently of this, the minimum requirements for the respective materials of the surface protection systems defined in this standard shall be met
The usefulness of the stored or processed medium may not be impaired by the surface protection system Special requirements for this are not part of this standard
10.1.2.1 Fluid load, chemical resistance and tightness
The lining must be secure and durable enough to withstand the anticipated fluid load as specified in Clause 4 Additionally, it is essential to consider the impact of the vapor phase, as well as the influence of abrasive materials, such as suspensions and cleaning agents.
The testing and evaluation of the test results shall be performed according to 10.2.3
The lining shall withstand the expected thermal load from influence of the media or other sources of heat (e g heat radiation)
The testing and evaluation of the test results shall take place according to 10.2.4
The lining shall be resistant to the expected weather-related load and temperature change load caused by exposure to the medium, operating conditions or cleaning processes
The testing and evaluation of the test results shall be performed according to 10.2.5
In general, Linings are resistant to regularly expected mechanical loads according to load grades 1 (pedestrians), 5 and 6 (hydrostatic pressure) according to 4.2.6
Linings without additional protection are not suitable for mechanical loads of load grades 2, 3 and 4 according to 4.2.6
If traffic cannot be avoided the lining needs a protective coating or a combined lining according to prEN 14879-6 shall be used
Crack bridging is no problem for thermoplastics and rubber linings For all others like, for example duroplastics,
EN 14879-3 could be referenced for testing
Linings stuck over the whole area shall adhere to the substrate over the whole area
Mechanically anchored linings shall remain permanently bonded with the concrete substrate
Testing and evaluation of the test results takes place according to 10.2.6
Fastening elements for loose linings shall be resistant to the effects of the media or permanently protected against them
The lining shall be resistant to ageing processes due to heat and possibly due to weather-related temperature change loading
The ageing behaviour of linings made from PE-HD, PIB, PP, and PVDF, as well as pre-vulcanised soft rubbers, is well-established at room temperature Additionally, the effects of high temperatures on ageing behaviour are validated through fluid load tests conducted at operating temperatures, as outlined in section 10.2.3.
All other linings shall be tested and the test results evaluated according to 10.2.7
When using outdoors, the lining shall be resistant to weather influences
With the test according to 10.2.7 satisfaction of the requirements of grade 1 (according to 4.2.7) shall be proven
With the test according to 10.2.8 satisfaction of the requirements of grade 2 (according to 4.2.7) shall be proven
All materials coming into contact with the concrete shall be able to withstand the expected alkaline load from the substrate and shall not attack it chemically
Linings of PE-HD, PVC-U, PP and PVDF are compatible with concrete
For linings adhered across the entire surface, the adhesive system must be compatible with concrete Compliance with these standards is confirmed through a positively assessed weathering behavior test as outlined in section 10.2.8, utilizing a test panel in accordance with section 10.2.2.3.
Other test methods may be agreed
10.1.2.10 Behaviour in cleaning and neutralisation processes
The lining shall be resistant to expected cleaning and neutralisation agents
The cleaning procedure must be mutually agreed upon by the manufacturer and the user, with experience serving as the primary basis for evaluation Additionally, tests may need to be conducted on the loaded component in accordance with section 10.2.9.
The lining shall be resistant to the effect of micro-organisms
Linings must be resistant to micro-organism effects in areas with normal soiling and moisture For thermoplastic linings, such as PVC-P, their resistance should be evaluated in accordance with section 4.2.3 of EN ISO 846:1997, especially when exposed to atmospheric conditions.
Special single tests shall be agreed for expected special loads by micro-organisms, e.g in industrial sewage plants, bioreactors or composting plants
Linings shall be resistant to tension tears under consideration of the single application The requirement is considered met for soft rubbers, PIB and PVC-P
The test shall be performed according to 10.2.10
10.1.2.13 Capability of dissipating electrostatic charges
In plants handling flammable, highly flammable or extreme flammable liquids the linings may not lead to ignition hazards as a result of electrostatic charges
The requirements are considered met when
dissipating resistance of the lining at every point does not exceed [1 × 10 8 ] Ω or
volume resistance does not exceed [1 × 10 8 ] Ω and the insulation resistance (surface resistance) does not exceed [1 × 10 9 ] Ω
The test is conducted according to 10.2.11
If resistance measurements cannot be made or the dissipation of electrical charges can be ensured by other comparable measures, the meeting of these requirements shall be proven
Other requirements from other areas, e.g explosion protection or ESD applications are not an object of this standard
The requirements for the behaviour in fire shall be defined plant-specifically according to industrial safety and building legislation requirements
Secondary containment linings must comply with building material grade E-d2 as per EN 13501-1 For the storage of flammable liquids, these linings should be securely fastened to prevent slipping on vertical or inclined surfaces at temperatures up to 200 °C This requirement is satisfied if the lining is shielded by a wall or a similar mineral cover that is at least 50 mm thick and resistant to being displaced by wind or washed away by rain.
The test shall be performed according to 10.2.12.
Tests
The following tests apply exclusively to the suitability of the surface protection systems for the area of application according to Clause 4
Verification of suitability can be given by a) laboratory examinations by a testing laboratory or b) proof of facts established by experience of the owner or manufacturer or c) combination of both a) and b)
To verify suitability, the selected test procedures outlined in section 10.2.3.4 must be documented in the test report Specimens, along with their respective materials for laboratory testing, should be prepared in collaboration with the testing laboratory The testing laboratory must receive adequate proof of material identity through the specification of physical-chemical parameters, and individual verification can also be provided using certified reference objects.
The following can be considered as proof of experience according to b):
Laboratory examinations with recorded and reproducible results
Reference objects with comparable load conditions which are proven executed with the surface protection system the suitability of which is to be verified
Resistance lists the basic conditions of which are known and can be proven by laboratory tests
An overview of the necessary suitability verification is given in the normative Annex D Reference is made to the normative Annex E with regard to the material/media combinations
As specimens, sheet sections, completely bonded linings on concrete test panels and test panels with embedded anchoring elements are used
The lining thickness to be tested should be taken from Table 9
Table 9 — Thickness of the linings to be tested
Soft rubber sheets Completely bonded ≥ 2 the smallest used thickness
Completely bonded ≥ 2 the smallest used thickness
PVC-U Mechanically anchored ≥ 3 the smallest and the largest used thickness a
PE-HD Mechanically anchored ≥ 3 the smallest and the largest used thickness a
PP Mechanically anchored ≥ 3 the smallest and the largest used thickness a
PVDF Mechanically anchored ≥ 3 the smallest and the largest used thickness a
Thermoplastic sheets for loose linings
— ≥ 2 the smallest used thickness a a With mechanically anchored linings the largest sheet thickness should only be tested when there are differences in the rated thickness > 50 %
Special specimens may have to be used to test the behaviour in fire
Sheeting sections with and without joints should be used for testing
Test panels made of reference concrete type MC (0.4) according to EN 1766 shall be used to test completely bonded linings
Recommended minimum panel size: 300 mm × 300 mm × 40 mm
According to EN 14879-1 and section 7.1, the lining must be fully bonded to the test panels, whether it has joints or not, in accordance with the manufacturer's specifications It is essential to document the precise work procedures, including room climate, material consumption, priming, leveling mortar, adhesive application, and waiting times.
10.2.2.4 Test panels with embedded anchoring elements
Test panels featuring embedded anchoring elements must be manufactured in accordance with the manufacturer's specified method Specimens, both with and without joints, should be cut from these panels, with a minimum size of 300 mm × 300 mm × 60 mm, depending on the nap form.
10.2.3 Fluid load, resistance and tightness
The test will be performed in accordance with the designated grade and the specified test method outlined in Table 12 It is conducted at a temperature of + (23 ± 2) °C, following a minimum pre-conditioning period of 16 hours for the test samples in a standard climate of 23/50-2, as per ISO 554.
For load grades 5 and 6, the test shall be made at the temperatures of the operating medium
The chemical resistance of the lining against the thermal load caused by the media according to 10.2.4.1 is proven with this test
Testing of the fluid load of a higher load grade includes proof of resistance of the lining at a lower load grade, see Table 10
Table 10 — Area of validity of the fluid load tests
Verification of load grade according to Clause 4 Includes verification of load grade according to Clause 4
The media test is to be conducted with the fluid against which the lining shall be tight and resistant
Fluids can be categorized into specific groups based on concentration limits to verify their compatibility with material/media combinations as outlined in Annex E For testing, the designated test fluid in this annex is adequate Additionally, the media lists for rubber linings in Annex F are applicable for fully bonded soft rubber linings during fluid load tests at load grades 3, 5, and 6.
10.2.3.3 Evaluation of the test results
Following the liquid exposure test using one of the specified methods, it is essential to evaluate alterations in material parameters, including changes in mass, hardness, and potentially adhesion strength.
Material parameters are established through various testing methods: a) tension tests following ISO 37 or ISO 23529 on standard rod S 2 for elastomers produced after storage; b) tension tests in accordance with EN ISO 527-3 using specimen 5 at a testing speed of 200 mm/min for other materials; and c) Shore A hardness measurements for soft rubber linings as per EN ISO 868.
The permissible changes in material parameters can be taken from Table 11 and evaluated according to this section
Table 11 — Permissible changes in relation to as-delivered state
Fluid load/Load grade NR, CR, IIR, BIIR, CIIR,
PIB, PVC-P, PE-LD PE-copolymer
PE-HD, PVC-U, PP, PVDF
After conditioning in normal climate 23/50-2 for 7 days
Change in tear strength or yield stress
After conditioning in normal climate 23/50-2 for 7 days
Change in elongation at tear or yield strain
After conditioning in normal climate 23/50-2 for 7 days
5, 6 — ± 15 ± 15 a Under consideration of the course of the curve
The following may be taken into account in the assessment of changes in hardness of soft rubber linings (see Figure 1):
Change in hardness of 20 % of the initial value can be considered permissible
If the hardness change of the rubber lining falls between 20% and 50% of its initial value, it is ground down to 75% of its original thickness for suitability testing A remaining hardness measurement of 70% of the initial value indicates that the change in hardness is acceptable; otherwise, it is deemed unacceptable.
If the change in hardness is more than 50 % of the initial value, the change in hardness is not permissible
Figure 1 — Assessment of the changes in hardness of soft rubber linings to estimate their resistance to fluid load
Sufficiently stable sheet sections according to 10.2.2.2 shall be used as specimens
A cylinder filled with test fluid shall be placed on the specimen The test fluid shall be allowed to act on the specimen for 72 h
10.2.3.4.1.3 Evaluation of the test results
The test fluid may not penetrate the specimen
Sheet sections according to 10.2.2.2 should be used as specimens
The test follows the guidelines of EN ISO 175, with specimens immersed in the test fluid for the durations outlined in Table 12 It is essential that the specimens are fully submerged in the test fluid throughout the immersion process.
After the immersion test, specimens are brought to room temperature by quickly placing them in fresh test fluid for 15 to 30 minutes Following rinsing and wiping, changes in mass and mechanical parameters are assessed Measurements are then repeated after a 7-day conditioning period in a normal climate of 23°C and 50% humidity, as specified by ISO 554.
10.2.3.4.2.3 Evaluation of the test results
The values obtained post-immersion will be compared to the material parameters of the unloaded sheet Any deviations from the as-delivered state after loading must not exceed the limits outlined in Table 11.
Specimen according to 10.2.2.3 with a joint seam should be used
A cylinder filled with test fluid shall be placed on the lined test panel The test fluid shall act on the lining for
10.2.3.4.3.3 Evaluation of the test results
The adhesion strength is evaluated based on ISO 813 using both unloaded and loaded sample panels, with the peeling test performed directly across the jointing seam For soft rubber linings, the minimum permissible adhesion strength after fluid exposure is 1.5 N/mm Additionally, the reduction in adhesion strength for PIB and PVCP linings must not exceed 25% of the reference sample.
Specimens according to 10.2.2.3 with jointing seam shall be used
Two test panels are secured in a testing device, following the EN 977 standard, with one panel immersed in the fluid phase and the other in the gas phase Both panels undergo exposure for a duration of 90 days.
10.2.3.4.4.3 Evaluation of the test results
After exposure to test fluid, the test panels are assessed visually No damage such as tears, air bubbles, etc may be visible
The adhesion strength is determined according to EN 14879-4 on an unloaded and a loaded test panel The drop in adhesion strength may not be more than 25 % of the reference sample
This test serves as a fundamental assessment for soft rubber linings, demonstrating their suitability for load grades 5 and 6 when exposed to liquids.
If the initial test yields positive results, a more efficient method can be employed to assess the soft rubber lining's resistance to various liquids by testing circular specimens.
Samples bodies according to 10.2.2.3 with jointing seam are used for the basic test
Four further specimens in the form of circles with a diameter of 36 mm shall be used to determine the mechanical parameters
A test in a test device, e.g according to EN 977 shall be conducted over 90 days to assess the media effect in the liquid and in the vapour phase
This test shall be conducted with the media in Table E.1 as a basic test
In addition four circles shall be immersed in the test fluid in the test device until reaching weight constancy but at least for 28 days
10.2.3.4.5.4 Evaluation of the test results
The test panels are inspected visually after being exposed to the test fluid No damage such as tears, air bubbles etc should be visible
Load profiles and suitable surface protection systems for floors and walls
Table B.1 presents load profiles for elements with minimal climatic exposure, primarily subjected to fluid loads of grades 1 and 2 These elements experience only slight increases in surface temperatures and minimal temperature fluctuations, allowing for surface protection that requires only moderate levels of safeguarding.
Examples of these elements are:
floors in storerooms for solid bulk materials or liquid chemicals in laboratory batches;
floors in laboratories, control rooms and the like;
floors in production areas with closed operation;
walls in production and storage areas;
ceilings in production and storage areas
Table B.1 — Load profiles and suitable surface protection for floors and walls
Type of surface protection Chemicals as in
Grade of fluid load (as in 4.2.3)
Grade of temperature change (as in 4.2.5)
Grade of mechanical load (as in 4.2.6)
Grade of climatic influences (as in 4.2.7) Coating Lining Composite
I and II 1 20 to 70 1 to 4 3 0 to 1 A — R
I and II 1 20 to 70 1 to 4 4 0 to 1 A — R
I and II 2 20 to 70 5 1 to 4 0 to 1 A — R
A: suitable alternative surface protection, depending on the durability of the system
N: not recommended as surface protection
Load profiles and suitable surface protection systems for secondary containments
Table B.2 presents load profiles for elements situated both indoors and outdoors, which may need to handle significant fluid volumes temporarily in the event of operational failure.
Examples of such elements are:
secondary containments and areas near storage tanks;
storage areas for small drums and pallets;
Table B.2 — Load profiles and suitable surface protection for secondary containments
Type of surface protection Chemicals as in
Grade of fluid load (as in 4.2.3)
Grade of temperature change (as in 4.2.5)
Grade of mechanical load (as in 4.2.6)
Grade of climatic influences (as in 4.2.7) Coating Lining Composite
I and II 3 20 to 70 5 0 to 1 0 to 2 A A R
I and II 3 20 to 70 5 2 to 4 0 to 2 N N R
A: suitable alternative surface protection, depending on the durability of the system
N: not recommended as surface protection
Load profiles and suitable protection for production plant floors
Table B.3 presents load profiles for elements exposed to various forms of moisture, such as wetness, puddles, trickles, and condensation These elements necessitate long-term protection and sealing to ensure their durability Typical examples of such elements include those designed for both indoor and outdoor environments.
production area floors where open plant operation involves considerable leakage and dripping;
Table B.3 — Load profiles and suitable surface protection for production plant floors
Type of surface protection Chemicals as in
Grade of fluid load (as in 4.2.3)
Grade of temperature change (as in 4.2.5)
Grade of mechanical load (as in 4.2.6)
Grade of climatic influences (as in 4.2.7) Coating Lining Composite
I and II 4 20 to 70 1 to 4 3 0 to 2 N N R
I and II 4 20 to 70 1 to 4 4 0 to 2 N N R
I and II 4 20 to 70 5 1 to 4 0 to 2 N N R
A: suitable alternative surface protection, depending on the durability of the system
N: not recommended as surface protection
Load profiles and suitable protection for collecting basins, gutters, channels, pipes etc
Table B.4 presents load profiles for elements exposed to flowing fluids, whether located indoors or outdoors Open structural elements may experience additional mechanical loading due to traffic, necessitating long-term surface protection and sealing for both open and covered structures These elements are generally subjected to hydrostatic pressures of up to 0.05 bar.
Table B.4 — Load profiles and suitable surface protection for elements exposed to flowing fluids
Type of surface protection Chemicals as in
Grade of fluid load (as in 4.2.3)
Grade of temperature change (as in 4.2.5)
Grade of mechanical load (as in 4.2.6)
Grade of climatic influences (as in 4.2.7) Coating Lining Composite
I and II 5 20 to 70 1 to 4 3 0 to 2 N N R
I and II 5 20 to 70 1 to 4 4 0 to 2 N N R
I and II 5 20 to 70 5 1 to 4 0 to 2 A A R
A: possible alternative surface protection, depending on the durability of the system
N: not recommended as surface protection
Load profiles and suitable protection for containers
Table B.5 gives load profiles for containers with continual, long-term exposure to fluids, and also to hydrostatic pressure and mechanical loading Examples of such containers are:
Table B.5 — Load profiles and suitable surface protection for containers exposed to long-term hydrostatic pressure and mechanical loading
Type of surface protection Chemicals as in
Grade of fluid load (as in 4.2.3)
Grade of temperature change (as in 4.2.5)
Grade of mechanical load (as in 4.2.6)
Grade of climatic influences (as in 4.2.7) Coating Lining Composite
A: possible alternative surface protection, depending on the durability of the system
N: not recommended as surface protection
Sample form for acceptance inspection report
The copyright statement on page 1 prohibiting reproduction of any part of this standard does not apply to the following specimen form
Acceptance inspection report for lined concrete parts
C Checks after completion of application
Nominal value: mm Actual value: _ mm
D Testing carried out on test panels
Nominal value: _ Shore A/Shore D/Barcol Actual value: _ Shore A/Shore D/Barcol
Nominal value: _ N/mm 2 Actual value: N/mm 2
Overview of verification of suitability for linings
Table D.1 — Necessity of proof for the requirements
Load grade according to Clause 4
6 constant filling Section e.g laboratory floors, floors in technical rooms, walls e.g floors in closed production plants
Secondary containments e.g floors in production plants, galvanic plants, pump stations open gutters, trenches and appropriat e pump sumps closed gutters, trenches, pipes and pits containers
Fluid load, resistance and tightness
Behaviour in cleaning and neutralization processes
C Proof only for certain materials, media, versions or applications
D Covered by other proof + Suitable without proof
Test fluid groups for verification of suitability for material/media combinations
Table E.1 — Test fluid groups for verification of suitability for material/media combinations
1 a Petrol according to EN 228 with a maximum alcohol content of 5 %
47.5 vol.-% toluene, 30.4 vol.-% isooctane (2,2,4-trimethylpentane) 17.1 vol.-% n-heptane
3.0 vol.-% methanol 2.0 vol.-% tert butanol 1a a Petrol according to EN 228 with a maximum alcohol content of 20 % (including 1)
42.3 vol.-% toluene, 25.3 vol.-% isooctane (2,2,4-trimethylpentane) 12.7 vol.-% diisobutylene
4.2 vol.-% ethanol 15.0 vol.-% methanol 0.5 vol.-% water
2 b Aviation fuels a) Aviation fuel 100 LL b) 50 vol.-% toluene,
5 vol.-% ethanol c) Aviation turbine fuel Jet-A1 with additives (Nato- Code F-34)
3 Heating fuel oil EL unused combustion engine oils, unused vehicle gear oils, aliphatic and aromatic hydrocarbons with an aromatic content of ≤ 20 wt.-% and a flash point of > 55 °C
80 vol.-% Diesel fuel according to EN 590
3a c Diesel fuel according to EN 590 with a maximum content of 5 % Biodiesel (including 3)
76 vol.-% Diesel fuel according to EN 590
5 vol.-% Rape-oil fatty acid methyl ester (RME) 3b c Diesel fuel according to EN 590 with a maximum content of 20 % Biodiesel (including 3 and 3a)
64 vol.-% Diesel fuel according to EN 590
20 vol.-% Rape-oil fatty acid methyl ester (RME)
4 Raw oils 10.0 wt.-% Iso-octane
10.0 wt.-% toluene 20.0 wt.-% heating fuel oil EL 10.0 wt.-% 1-methyl naphthalene (min 96 %) 47.7 wt.-% heating fuel oil S
0.2 wt.-% thiophene (99 %) 0.3 wt.-% dibenzene sulfide 0.5 wt.-% dibutyl disulfide (97 %) 1.0 wt.-% naphthalic acid mixture (acid factor 230) 0.1 wt.-% phenol
0.2 wt.-% pyridine Mixed with 2.0 wt.-% water
5 d All hydrocarbons including benzene and benzene mixtures
10 vol.-% methyl naphthalene 5a e All hydrocarbons as well as used combustion engine oils and used vehicle gear oils with the exception of raw oils, benzene and benzene mixtures
10 vol.-% methyl naphthalene 5b — used combustion engine oils and
— used vehicle gear oils with a flash point > 55 °C
80.0 wt.-% motor oil based on mineral oil 10.0 wt.-% toluene
9.9 wt.-% water 0.1 wt.-% anionic tenside sodium dodecylsulfate
6a halogen hydrocarbons = C 1 dichlormethane (methylene chloride)
7 all alcohols and glycol ethers (including 7a) methanol
7a single and multiple value alcohols (up to max 48 vol.-% methanol), glycol ether (including 7b)
8 f all organic esters and ketone (including 8a and 8b) 50 vol.-% ethyl acetate
8a aromatic ester and ketone 50 vol.-% methyl salicylate
8b Biodiesel Rape-oil fatty acid methylester (RME) (summer quality)
9 aliphatic aldehydes and their aqueous solutions (incl 9a) 50 vol.-% n-butyl aldehyde (Butanal)
50 Vol.-% n-heptaldehyde (Heptanal) 9a aqueous solutions of aliphatic aldehydes up to 40 % 35 - 40 % commercially available aqueous formaldehyde solution
10 cyclic and acyclic ether (including 10a) tetrahydrofurane (THF)
11 amines and their salts (in aqueous solution) 35 vol.-% triethanolamine
12 g organic acids (carboxylic acids, except formic acids) and their salts (in aqueous solution)
50 vol.-% propionic acid 12a g aqueous solutions of organic acids (carboxylic acids) to
10 % as well as their salts (in aqueous solution)
13 g mineral acids up to 20 % as well as acetic hydrolysing inorganic salts in aqueous solution (pH < 6), except hydrofluoric acid and oxidizing acids and their salts
Sulphuric acid (20 %) Hydrochloric acid (20 %) should be used for testing inside linings of containers
14 g inorganic lies as well as alkaline hydrolysing inorganic salts in aqueous solution (pH > 8), except ammonia solutions and oxidizing salt solutions (e.g hypochlorite)
Sodium hydroxide (20 %) Sodium hydroxide (1 %) should be used additionally for testing inside linings of containers
15 g aqueous solutions of inorganic non-oxidizing salts with a pH value between 6 and 8 aqueous sodium chloride solution (20 %)
16 aqueous solutions of organic tensides 3 % solution of sodium laurylether sulphate
[C 12 H 25 -O-[(CH 2 ) n -O] m -SO 3 ]Na and sodium chloride in water
2 % of a fluid consisting of about 99 wt % of a fat alcohol polyglycol ether R-O(CH 2 CH 2 O) n H (ethoxylation factor n ≈ 8; as a mean value) in addition to small quantities of polymerised ethylene oxide ( ≤ 1 wt %)
Suitability for group 1 is confirmed if tests with fluids from groups 5a or 5 and 7a or 7 are successful All test fluids must be used for testing, and suitability is only established when testing is conducted with a single fluid Passing tests with groups 3 and 8 or 8b additionally confirms suitability for groups 3a and 3b Furthermore, passing the test with group 5 fluid extends suitability to groups 2, 3, 3a, 4, 5a, and 5b Similarly, passing the test with group 5a fluid extends suitability to groups 2, 3, 3a, and 5b For load grade 6, a test with pure acetone is required If higher concentrations are allowed, tests with groups 12 and 12a confirm suitability for all organic acids in aqueous solution, except for formic acid above 10% For mineral acids in group 13, testing must include both the appropriate test fluid and the maximum concentration desired, covering the mineral acid up to the tested maximum concentration Lastly, proof of suitability for group 15 is confirmed if tests with fluids from groups 13 and 14 yield positive results.
Media lists for elastomer linings
To utilize the media lists, tests must be performed in accordance with section 10.2.3.4 using the test fluids specified in Table F.1, ensuring that specimens are stored until they reach weight constancy These media lists are applicable to load grades 3, 5, and 6 concerning fluid effects.
Table F.1 — Test fluids for the application of the media lists for elastomer linings
Media list for soft rubber from Test fluid Test temperature
Pure butyl or halogen butyl rubber 50 % sodium lye 40 °C
The following media lists contain aqueous, technically pure fluids which may be used up to a temperature of
40 °C providing there are no restrictions noted in the list If no concentration restriction is specified, every possible concentration is covered
I Media list for soft rubber of IIR (pure butyl or halogen butyl rubber) with a maximum content of 10 % other rubber related to the total rubber content; max storage temperature + 40 °C
1 Aqueous solutions of non-oxidising inorganic salts, pH value from 6 to 8
2 Inorganic lye as well as alkaline hydrolysing inorganic salts in aqueous solution, pH > 8, except ammonia solutions and oxidising salt solutions, e.g hypochlorite
3 Aqueous solutions of acetic hydrolysing non-oxidising inorganic salts, pH < 6
4 Hydrochloric acid ≤ 30 %, permanent maximum storage temperature 25 °C
7 Hexafluorosilic acid ≤ 30 %; ≤ 40 %, permanent maximum storage temperature 30 °C
9 Ammonia solutions ≤ 25 %, permanent maximum storage temperature 25 °C
The media list for polychloroprene rubber includes a maximum of 10% of other rubber types relative to the total rubber content This also applies to mixtures with butyl rubber (IIR), whether pure or halogenated, regardless of the mixing ratio Additionally, the maximum storage temperature for these materials is +40 °C.
1 Aqueous solutions of non-oxidising inorganic salts, pH-value of 6 to 8
2 Inorganic lye as well as alkaline hydrolysing inorganic salts in aqueous solution, pH > 8, except ammonia solutions and oxidising salt solutions, e.g hypochlorite
3 Aqueous solutions of acetic hydrolysing, non oxidising salts, pH < 6
6 Hexafluorosilic acid ≤ 40 %, permanent maximum storage temperature 30 °C
8 Ammonia solutions ≤ 25 %, maximum permanent storage temperature 25 °C