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SewperCoat®

SewperCoat® is a technological breakthrough in the market of cementitious materials designed for the municipal wastewater industry. It provides high-strength, corrosion-resistant protection against biogenic corrosion caused by hydrogen sulfide (H2S) found in wastewater environments. This type of degradation is referred to as Microbiologically Induced Corrosion (MIC). 

SewperCoat® provides a high early strength (> 6,000 psi compressive strength within 24 hours), resulting in both a high-strength, corrosion resistant lining from a single installation. Once applied, the unique mineralogy of SewperCoat® inhibits bacterial (Thiobacillus) activity, minimizing the production of sulfuric acid (H2SO4).  This process results in a locally raised surface pH in a wastewater structure.  This bacterial inhibiting phenomenon is referred to as the “Protective Reactive Barrier Effect” of SewperCoat®

SewperCoat® is a 100% pure calcium aluminate premix used for the rehabilitation of sewerage structures.  It is also used as a lining for most wastewater structures in new construction applications. Because it is 100% calcium aluminate there is no “weak link” in the material to cause potential problems in the H2S environment.

SewperCoat® is composed of both calcium aluminate cement and manufactured calcium aluminate aggregates.  The unique mineralogy of the cement and aggregates are the key to its ultimate performance.  Both the calcium aluminate cement and aggregate system of SewperCoat® are of the same chemical and mineralogical nature.  Upon hydration, both a physical and chemical bond is achieved between the cement and aggregates. 

SewperCoat® is a very cohesive mortar that possesses excellent thin section toughness, and high early flexural and compressive strengths. It contains no Portland cement or its hydrates (calcium hydroxide). The outstanding performance of SewperCoat® results from the unique chemical and mineralogical phases formed during hydration.

SewperCoat® is designed to be spray applied in the field with either dry-gunite or low-pressure, wet shotcrete equipment.

Please contact Kerneos™ for specification recommendations and a listing of competent and qualified SewperCoat® applicators in your area.


SewperCoat® is available in two formulations.  Both of these formulations contain pure calcium aluminate cement and aggregates.  The differences in each are based on the formulation’s aggregate gradation.  Each formulation of SewperCoat® is designed for a specific application method and its specific installation equipment.  The formulations are as follows:


SewperCoat® 2000 HS Regular is specifically formulated for the “dry-gunite” application method.  Material should be installed in accordance with standard industry practice as defined by ACI 506 – Specifications for Materials, Proportioning, and Application of Shotcrete.

Recommended installation thickness is a minimum 1/2-inch in manhole applications and a 1-inch minimum in larger, more critical structures.

Equipment must be a high velocity, dry-gunite machine that is clean and free of any Portland cement residue.

Gauged Water must be clean and potable. Use approximately 0.5 gallons for each 50-pounds of material used.

Finishing should be kept to a minimum. A "gunned" finish is preferred to prevent "tearing" during troweling.

Curing by appropriate methods (curing compound, water mist, etc.) should be implemented as the surface begins to harden and dry (as early as one hour after application).

Packaging: SewperCoat® 2000HS Regular is normally provided in 50-lb. bags. It must be covered and stored in a weather-protected area, free from moisture.


SewperCoat® PG is specifically formulated for the “wet-shotcrete” application method.  This installation equipment is typically a low-pressure progressive cavity (rotor/stator) type pump.  This formulation is ideal for confined spaces due to its low pressure and minimal rebound characteristics.  Material should be installed in accordance with standard industry practice as defined by ACI 506 – Specifications for Materials, Proportioning, and Application of Shotcrete.

Recommended installation thickness is a minimum 1/2-inch in manhole applications and a 1-inch minimum in larger, more critical structures.

Equipment must be a low-pressure, wet-spray machine that is clean and free of any Portland cement residue.

Gauged Water must be clean and potable.  Use approximately 1.1 gallons for each 65-pounds of material used.  

Curing by appropriate methods (curing compound, water mist, etc.) should be implemented as the surface begins to harden and dry (as early as one hour after application).

Packaging: SewperCoat® PG is normally provided in 65-lb. bags. It must be covered and stored in a weather-protected area, free from moisture.


Calcium aluminate has been used for municipal applications for over 70 years. SewperCoat® consists of both calcium aluminate cement and calcium aluminate aggregate. This combination is the key to the ultimate performance.

SewperCoat® offers the premium mineral solution for concrete corrosion problems caused by biogenic activity commonly found in municipal sewer environments. Due to its 100% calcium aluminate mineralogy and overall chemistry, it has been documented that SewperCoat® out performs other cementitious-based technology currently marketed for concrete corrosion protection in a wastewater environment. 

SewperCoat® is the original product in this market utilizing 100% calcium aluminate cement and calcium aluminate aggregate system.  SewperCoat® has the only 100% calcium aluminate “dry-gunite” formulation available in this market.  Other products that merely state to be "calcium aluminate" may contain blends of various aggregates and fillers that do not duplicate the chemistry or performance of SewperCoat®.

Extensive worldwide research has been conducted at the University of Hamburg, Germany, involving various cementitious products and their ability to protect against biogenic corrosion. Only one pure calcium aluminate product, SewperCoat®, has been included in this research with documented results.

We recommend to end users in the municipal sewer industry, that they require the submittal of a complete chemical analysis of products claiming to be cementitious based (including calcium aluminate products), along with documented performance results in a bacteriological (biogenic) corrosive environment. In our opinion, such information is essential to properly compare the performance of other competitive products to SewperCoat®.

Documents
Product Data Sheet (2000 HSR) 
Product Data Sheet (PG)
Safety Data Sheet (2000 HSR)
Safety Data Sheet (PG)
SewperCoat® References

All product data sheets and material safety data sheets are provided below in Adobe's Portable Document Format (PDF). To view these documents, you will need Adobe Acrobat Reader; if you do not have it, follow the link below to download a copy.

http://www.adobe.com/prodindex/acrobat/readstep.html

You may also receive a copy of any of these documents 
by contacting our marketing department at
(757) 284-3200

Cements include: Formulated Products include: Specialty Products include:
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