Materials of Construction - Acid Resistant Linings - Lining Installation
May 9, 2003

Introduction Installation Contractor Material Material Storage Installation Final Inspection

Associated Links Installation Specification Installation Details

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Introduction

The success of an acid resistant lining in a tower or pump tank is dependent on the following factors:

• Material selection
• Proper design
• Proper specification
• Proper material substitution during installation
• Proper storage and protection of material
• Proper installation methods

The first three items are the responsibility of the designer while the remaining items are the responsibility of the installation contractor.

Installation Contractor

Employing the services of a contractor experience in the installation of acid resistant lining is essential.  A contractor who lays bricks for residential construction does not have the skills and knowledge to install an acid resistant lining. 

The supplier of the acid resistant lining material will often provide a supervisor to oversee the installation of the lining.   A contractor experienced in this type will be hired locally to provide the labour.   All work will generally be done under the supervision of the supplier who will inspect the work daily to ensure that the lining is being installed as per the design.

The installation contractor should provide at least a one year warranty against defects in workmanship.

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Material

The quality of the material is one of the keys to ensuring that the lining performs as required.

At the design stage the material being offered by the bidders should be checked to ensure it complies with the specification.   Bidders may offer material of lower quality in order to present the lowest price.   Manufacturer’s specifications and literature for all materials should be reviewed.

At the job site, the materials should be checked to ensure that the materials received are those specified in the purchase order.   This will ensure that lower quality materials have not been substituted.  If there is any doubt about the quality of the materials, samples should be taken and tested.  

A thorough inspection of the material and packaging should be performed.  If the packaging has been damaged checks should be made to ensure that the material has not been affected by dirt or moisture.  If dirt is found on the brick pallets, the bricks should be examined to ensure they are clean.   If significant amounts of dirt are found, a program should be set up by the installation contractor to clean the bricks.

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Material Storage

The handling and storage procedures specified by the manufacturer should be followed exactly to avoid damage to the material.   The following requirements for storage and handling are generally specified:

• Material to be stored indoors where it will be protected from the elements (i.e. dirt, snow, ice, moisture, condensation, etc.)
• Heated indoor storage to avoid exposure to low ambient temperatures.  Mortar which has become wet or frozen must be discarded.  Wet brick which has been frozen must also be discarded.
• Outdoor storage is only permitted if the material is adequately protected from the weather and ground moisture.

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Installation

An inspector should monitor the work to ensure that the correct materials and procedures are used.  The following are some of the things that the inspector must check:

• Inspect the tools for cleanliness at the beginning of each day.  At the end of the day all tools should be cleaned.
• Monitor the consumption of material to ensure that the amount of material consumed is in line with the manufacturers recommendations.
• Inspect the materials to ensure that the correct materials were supplied and that the shelf life of the material has not expired.
• Check the installation conditions such as temperature, humidity, dust, etc.  Work should be stopped if the work area becomes wet.  Damaged material should be removed and the work area cleaned and dried.
• Observes the installation of the membrane to ensure it is done properly.  Ensures that the proper overlapped is achieved between sheets and that the membrane adheres properly to the substrate.  The inspector also conducts testing of the membrane for pinholes.  The membrane should also be inspected for blisters and bare spots.
• Checks that the bricks are correctly laid.  Brick should fit snugly into the space for which they were cut.  Irregular pieces should be discarded.  The use of chips or scraps to fill voids is not allowed.  Excess mortar is to be used on all joints.  The mortar should extrude from the joint as the brick is placed into its final position. 
• Check that the mortar has the correct consistency and is at the correct temperature.  Mortar that is too cold, stiff or old must be discarded.
• Check that surfaces are even and straight. 
• Check that mortar joints are the proper thickness.

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Final Inspection

Final inspection of the installation is primarily by visual means.  The following should be check during the final inspection prior to acceptance of the work. 

• Check the joints to ensure they are fully cured by trying to penetrate the joint with a small blade.
• Check for shrinkage of the mortar by looking for areas where the joint has separated from the brick.
• Probe the joints with a stiff wire to look for pits and air pockets.
• Tap the lining with a small hammer to locate voids.
• Over-troweling of a joint may indicate that insufficient mortar was used in the joint and the mason has attempted to cover over the faulty work.

The installation should not be accepted unless the installation fully meets the design and specification requirements.  All defects should be repaired to the satisfaction of the inspector and owner.

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