P. O. Box 801357
Santa Clarita, CA 91380-2316
Phone: 877.274.2422
Fax: 661.775.7628
www.CSIServices.biz
Providing Quality Technical Services to the Coating Industry Hawaiian Office: P.O. Box 671, Aiea, HI 96701
Northern California Office: P.O. Box 371, Sonoma, CA 95476 Coating Specialists and Inspection Services, Inc.
Consulting Evaluations Tank Diving Inspection
April 23, 2023 Via Email: [email protected]
Shawn Ryan, PE
City of San Clemente
910 Calle Negocio
San Clemente, CA 92673
Subject: Tank Paint Evaluation Services
Re: Reservoir No. 4
Dear Shawn:
Please find attached the final report for the evaluation that was completed on the above referenced tank. Thank you for your business and please let me know if you have any questions or comments about our findings. I can always be reached by cell at 661.478.8900 or by e-mail at [email protected].
Sincerely,
CSI Services, Inc.
Patrick Sweeney
Project Manager
$WWDFKPHQW
Hawaiian Office: P.O. Box 671, Aiea, HI 96701
Northern California Office: P.O. Box 371, Sonoma, CA 95476 Coating Specialists and Inspection Services, Inc.
Consulting Evaluations Tank Diving Inspection
P. O. Box 801357, Santa Clarita, CA 91380 • 877.274.2422 Final Report
Tank Paint Evaluation Services
Reservoir No. 4
Prepared for:
Shawn Ryan, PE
City of San Clemente
910 Calle Negocio
San Clemente, CA 92673
Prepared by:
CSI Services, Inc.
_________________
Patrick Sweeney
Project Manager April 23, 2023
Final Report – Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
Page i
Hawaiian Office: P.O. Box 671, Aiea, HI 96701
Northern California Office: P.O. Box 371, Sonoma, CA 95476 Coating Specialists and Inspection Services, Inc.
Consulting Evaluations Tank Diving Inspection
Table of Contents
Introduction ..……………………………..………….………… Page 1
Summary….........……………………...………..…….…...…… Page 1
Background........……………………...………..…….…...…… Page 2
Field Evaluation ……………………...………..…….…...…… Page 2
Laboratory Analysis.………………...………..…….…...…… Page 4
Discussion…..…………………………………………..……… Page 5
Recommendations………………………….....….……...…… Page 8
Photo Summary………..…………………….....….……...…… Page 9
Attachments
- CSI Chart 1 – General Description of Conditions
- CSI Chart 2 – Rust Grade Criteria
- CSI Chart 3 – Corrosion Grade Criteria
- CSI Chart 4 – Coating Chalking Criteria
- CSI Chart 5 – Coating Adhesion Criteria
- Laboratory Report
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Introduction
The City of San Clemente (City) authorized CSI Services, Inc. (CSI) to conduct a tank maintenance paint evaluation on Reservoir No. 4, located adjacent to 419 Avenida Salvador, San Clemente, CA. The focus of the evaluation was the condition of the paint system(s) to develop recommendations for maintenance coating activities. Maintenance recommendations have been made in accordance with the applicable requirements of American Water Works Association’s Standard (AWWA) D102 “Coating Steel Water Storage Tanks,” AWWA Standard M42 “Steel Water Storage Tanks,” Good Painting Practice, and CSI's experience with evaluating over a thousand water storage tanks. A Photo Summary is included to further document some of the conditions observed.
CSI is a third-party independent consulting engineering firm that specializes in tank evaluations with specific expertise in industrial protective coatings and linings. CSI provides many different services including failure analysis, expert witness, evaluations, specifications, in-process inspection, testing, and tank diving. Mr. Patrick Sweeney of CSI was assigned to manage the project and complete the fieldwork. He holds a Bachelor of Science degree and a NACE International Level III Coating Inspector certification. He is also certified by SSPC as a Level III Protective Coating Inspector (PCI), Protective Coating Specialist (PCS), and Master Coating Inspector (MCI). He has over 30 years of extensive experience evaluating tanks. Mr. Sweeney completed the field-work on Monday, April 10, 2023.
Summary
The paint on the exterior of Reservoir No. 4 is in poor condition with an extensive amount of rust development on the roof. The rust on the roof is primarily a result of excessive chalking, while the limited amount of rust on the shell is a result of impact damage to the paint from mechanical scrapes and thrown rocks. Although the paint on the shell has a minor amount of rust, it has poor intercoat adhesion (i.e. poor paint cohesion). The paint was also found to have moderate levels of heavy metals. The condition of the existing paint and the level of corrosion should not significantly change for more than 5-years, and it is recommended that the paint be removed and replaced within this time-frame.
CSI has also presented some comments and observations on the condition of the interior lining and some tank attributes that should be considered for repair or retrofitting prior to any new paint work.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Background
Reservoir No. 4 is a welded steel tank that is approximately 54-feet diameter by 32-feet high, providing a nominal capacity of approximately 500,000 gallons. The structure sits within a ravine between residences. Specifically, the tank is located at GPS coordinates
33.432305, -117.60164. The tank was built in 1962 by Consolidated Western Steel Corporation. The tank shell has four 8-foot courses connected to a slightly pitched roof with a drip-edge perimeter. The upper shell course below the drip edge has approximately 20 perimeter vents that involve mesh-grating secured by a bolt fastened steel frame. The tank has a center roof vent, and one round uni-bolt shell manway. The tank shell has one exterior ladder that leads to a roof access hatch. The ladder starts above the first course and has a fall prevention gage. The roof access hatch has an adjacent safety handrail that that extends a few feet to either side of the roof hatch. It is believed that the paint on the tank is the original coating applied, and it appears to be an alkyd based system.
The tank is not anchored to its concrete ringwall foundation. A mechanical water level indicator scale extends along the entire length of the shell. The lowest shell course has inlet/outlet piping that does not have flexible connections. The tank overflow exits the upper course, runs down the shell, and enters the ground without an air-break. There is a wood plank covered vault adjacent to the tank, and it is suspected that this is the location of a floor drain valve. The tank site has perimeter fencing, but the fencing is not believed to be continuous. A smaller fence encloses the tank access ladder area and an impressed current cathodic protection (CP) rectifier box. CP hand-hole covers were located on the roof. That tank has an adjacent pumphouse building comprised of painted CMU block and a simple tar shingle roof.
Field Evaluation
The purpose of this survey was to assess the condition of the coatings and recommend maintenance coating work, where needed. The evaluation involved visual observations, but also involved various testing procedures. For survey purposes, the large tank has been segmented into two defined areas: exterior roof and exterior shell. Samples were collected for laboratory analysis for heavy metals.
A rating system has been developed to quantify the condition of these various tank areas, and each of the rating criteria is found in the Attachments (Charts 1 through 6).
The condition of the coating systems was rated as being poor, fair, good, or excellent (Chart 1). The extent of any rust defects identified within each of the areas was generally determined using the guidelines set forth in ASTM D610 “Standard Test Method for Evaluating the Degree of Rusting of Painted Steel Surfaces” (Chart 2).
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Where applicable, the characteristic or stage of corrosion was determined in accordance with CSI Corrosion Grade criteria (Chart 3). The degree of paint chalking was determined in accordance with ASTM D4214 “Standard Test Method for Evaluating the Degree of Chalking of Exterior Paint Films,” Test Method D659, Method C (Chart 4).
Coating adhesion was assessed in accordance with ASTM D3359 “Standard Test Method for Evaluating Adhesion by Tape Test, modified Method A and/or a modified version of ASTM D6677 “Standard Test Method for Evaluating Adhesion by Knife” (Chart 5). The modified version of ASTM D6677 was used in areas where destructive testing was not found to be practical, and the coating dry film thickness (DFT) was measured with a Positector 6000FN3 Type II gage in accordance with the applicable guidelines set forth SSPC PA2. The visual observations and data collected follow:
Tank Exterior
Close-up visual observations of the paint were limited to the first (lowest) shell course, upper shell areas adjacent to the ladder, and the roof. The exterior paint on the roof and its appurtenances is in poor condition with heavy chalking (ASTM D4214, No. 4) and large fields of dark rust (CSI Corrosion Grade 2). The roof access hatch throat was found to have more advanced corrosion with some pitting and scaling corrosion (CSI Corrosion Grades 3 and 4). Spray patterns from the original paint application work was evident by an underfilm shadowing through a severely thinned finish, and underfilm rust was also evident at the thinnest locations. Some areas of paint had severe cracks with dark rust. The center vent opening appeared to have a continuous and secured screen in place. The screen included a small mesh screen protected by a perforated galvanized grating that was bolted in place. The roof rail assembly had rust present in some areas, but no significant metal loss was observed. The tank roof has a galvanized pole that has an antennae with a cable that extends to the adjacent pumphouse. The amount of corrosion on the roof was estimated to be more than half of the total surface (ASTM D610, 1). The dry film thickness (DFT) of the paint on the roof was measured to range from between 1.5 and 5 mils in areas with an intact and continuous film, and the film adhesion in these areas was poor (ASTM D6677, 4). A paint sample was collected from the roof and labeled CSI -1 for laboratory analysis for heavy metals.
The exterior shell paint is in poor to fair condition with heavy chalking (ASTM D4214, No. 4) and scattered dark rust spots (CSI Corrosion Grade 2). The shell has a relatively minor amount of rust, and the few rust spots appears to be the result of coating breaks from mechanical damage and thrown rocks. The upper shell vents have a few feet of rust staining running down the upper course. This exterior leading edge of the floor plate (lower chine) was free of any notable advanced corrosion, but most of the chine had dark rust where the paint had flaked away to expose bare metal. The lower few feet of the tank shell also had a flaky paint that extended from a light blue undercoat. The paint DFT on the shell was measured to range from between 5 and 7 mils. The film adhesion was found to be poor (ASTM D6677, 2), and the weak bond was between the upper Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
paint and a red primer that was measured to be less than 1-mil thick. A paint sample was collected and labeled CSI -2 for laboratory analysis for heavy metals. The water level indicator does not appear to be properly operating.
Tank Interior
The tank interior was not part of the scope of this evaluation, but a cursory evaluation of the interior was completed from a northern CP hand-hole. The hand-hole cover was found detached and resting on the adjacent roof plate, and was loosely reinstalled after the inspection. These internal surfaces have been included for informational purposes and should be considered cursory in nature.
The limited amount of interior surface examined noted that the underside of the roof, including the roof support structure appeared to be in mostly satisfactory condition with localized dark rust. Although most roof support structure edges seen appeared to be properly lined, rust was common to the upper chine, and the topside crevice between the upper rafter-beam and roof plate. Advanced corrosion was noted on the tension rod fasteners and on the secondary rafter tension brackets. The surface below the roof appeared to have a lining in satisfactory condition in that no rust was observed. The floor was noted to have a minor amount of sediment built up adjacent to the floor plate weld seams, btu also free of any notable corrosion. The CP components hanging from the roof appeared to be in satisfactory condition with respect to corrosion.
Laboratory Analysis
Paint samples were collected from the tank exterior to determine the presence of heavy metals (i.e. lead, cadmium, and chromium) in the paint films. Two (2) samples were sent to Schneider Laboratories, Richmond, VA for heavy metals analysis in accordance with EPA Method 3050B/6010B. A summary of the results reported in PPM (mg/kg) follows:
Sample ID Description
Element (ppm)
Cadmium
(Cd)
Chromium
(Cr)
Lead
(Pb)
CSI-1 4MG Tank – Exterior Roof <6.39 6310 6710
CSI-2 4MG Tank – Exterior Roof <5.99 4990 4820
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Discussion
The paint on the exterior of Reservoir No. 4 is in poor condition with an extensive amount of rust development on the roof. The rust on the roof is primarily a result of excessive chalking, while the limited amount of rust on the shell is a result of impact damage to the paint from mechanical scrapes and thrown rocks. Although the paint on the shell has a minor amount of rust, it has poor intercoat adhesion (i.e. poor paint cohesion). The paint was also found to have moderate levels of heavy metals.
Chalking is the term for the powdery characteristic of an aged coating that may also have a faded finish. Chalking is a result of the natural breakdown of a paint system's binder when it is exposed to sun, or ultraviolet (UV) light. The binder (or resin) degrades in UV, which leaves behind the unbound pigment, or chalk. Aside from a faded appearance, chalking can result in corrosion as the film weathers (thins) away through cycles of wind and rain. As the paint endures years of direct sunlight, it begins to weather away, which results in the paint no longer providing enough barrier protection from corrosion. The roof paint has chalked and significantly thinned to a level to where the primer has also been exposed in many areas. This thinning has resulted in fields of underfilm corrosion breaking through the roof paint.
Generally speaking, there are four possible approaches to maintenance coating work.
The coatings can be either completely removed and replaced (repainted), spot repaired, spot repaired and overcoated, or simply overcoated. In evaluating the condition of a coating to determine the best approach there are a number of different factors to consider. The first set of factors includes the determination of the coating's ability to withstand the added stress of an additional coat(s). Attributes impacting this decision include film thickness and adhesion. If a film is too thick or has poor adhesion, the tension from the curing stresses and/or the weight of the additional paint can cause the existing system to disbond. The second set of factors to consider when determining what maintenance coating approach to take is the amount of surface area requiring repair, the overall difficulty in providing access to the structure, and whether the coating system contains heavy metals. The final factor is the condition of the substrate.
When considering whether a spot repair approach is a viable option, a good rule of thumb is that up to 10 percent of the surface area requiring repair is the point at which making spot repairs with overcoat becomes a diminishing return. With 10 percent rusting, overcoating may be an option if the adhesion is better than fair. If there is more than 10 percent rusting and the substrate is free of mill scale, overcoating may be considered an option if the adhesion is satisfactory. Once the amount of surface area exceeds this range, the cost of cleaning and coating the individual rust spots approaches (or exceeds) the total cost of removal and replacement.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
The coating does not have the orangish-red primer often associated with lead-based paint, but it has been found to have moderate levels of the element chromium and lead.
The deterioration of this (heavy-metal bearing) paint, which historically provides decades of service before widespread rust develops, indicates the paint is the original paint system applied (more than 60 years old).
The tank paint is suspected of being an alkyd. Alkyd paints in the marine environment of the City should last approximately 35 years if they are not damaged. At this benchmark, the paint is often spot repaired and overcoated to extend the life of the paint, perhaps an additional 25 to 35-years before it might accept another round of maintenance painting. Unfortunately, this maintenance painting was never completed, and the maintenance window for paint work closed perhaps 25-years ago. The paint now requires removal and replacement. The condition of the existing paint and the level of corrosion should not significantly change for more than 5-years, and it is recommended that the paint be replaced within this time-frame.
The future painting project will be adjacent to the high-end neighborhood and a busy street. This will obviously result in significant interest from the community. The fact that moderate levels of heavy metal are present in the existing paint complicates its repainting. The removal of all the paint will require special considerations to protect not only the workers, but also the surrounding environment. These project attributes will likely include specially trained workers, full tank containment, and perhaps regulated waste handling.
The estimated cost of the painting work, as recommended above is $98,500.
With a few minor exceptions, the tank interior lining system inspected from the small roof opening appears to be performing properly. The exceptions involve the upper crevice’s and edges of the roof structure. As these locations continue to corrode, they will be the driving for tank relining work. The surfaces below the overflow roof are satisfactory, and this is a result of the proper (past) operation of the cathodic protection (CP) system. Unfortunately, the area above the overflow level does not benefit from the added protection of the CP system. It is recommended that the tank interior be inspected, perhaps with divers within the next 4-years. This maintenance inspection should pay special attention to the roof support structure’s condition to assure that tank coating defects will be corrected before steel replacement is required. It is believed that at least the bolts to some of the earthquake rods and tension bars will require replacement, as those inspected from the small opening have lost notable metal.
Although the scope of this assignment was the tank paint, some other tanks attributes associated with seismic, safety, and operational considerations have been noted for future consideration. The tank piping is rigidly connected to the tank. This includes the Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
lower shell inlet/outlet piping, and presumably the floor drain. During an earthquake, there is the potential for the tank (and tank bottom) to move at a different rate than the (below grade) piping. Past earthquakes resulted in these pipe connections being sheared or cracked, which resulted in a loss of water capacity during times when it was most needed during the emergency. The shell piping could be retrofitted with flexible connections for inlet/outlets, and the drain could be abandoned after the installation of a flush clean-out shell manway. This flush clean-out would provide a second manway for confined safety concerns and for better access when the tank is worked on in the future.
The overflow pipe outlet was not identified. The proper design of an overflow pipe on a potable tank should include a screened/sealed air-gap. The sealing is required to prevent animals from gaining access into the tank. This can be accomplished by simply installing screening over the outlet or installing a self-closing flapper valve. Furthermore, the pipe should not enter the ground directly, it should have an air-break or gap above grade to prevent the possibility of back-flow contamination.
The upper shell vents are not believed to be required for proper operation, notably given the relatively large center roof vent. Upper shell perimeter vents tend to be a maintenance issue resulting in rust at crevices and rust stain running down the shell.
Prior to any paint work, it is suggested that the upper shell vents be patched with steel plates. It should be understood that this process will also damage the interior lining in areas that are not protected by the CP system.
The water level indicator is not functioning properly. It should also be repaired with components that will not corrode if it is required for operations (i.e. SCADA is used).
Also, some CA health department offices require a mechanical level indicator in addition to a SCADA system.
The tank was found to have areas that could benefit from an upgrade to it fall prevention system. Ladder and roof rail systems should be designed to prevent the probability of a person falling. There are many designs that can be implemented to prevent a fall. The most cost-effective means would be to install a fall prevention system on the ladder (i.e.
Saf-T-Climb or Yo-Yo type lanyard system). Although, a 360-degree perimeter railing could also be installed on the roof, a more cost effective upgrade could involve a roof life-line at the center of the tank that could be used in conjunction with a climbing harness system to prevent any workers from advancing too close to the tank roof edge.
Although a fence is evident around the site, a healthy looking coyote was seen wandering around within the tank site. This indicates that there is a void within the perimeter fencing. This should be reviewed as part of any tank security concerns.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Recommendations
Tank Exterior
The following paint work is recommended to be completed within the next 5-years:
1. Remove and replace the paint system using an SSPC QP2 certified painting contractor.
A. Require full containment of the tank during all paint removal activities.
B. Prepare all surfaces in accordance with SSPC-SP6.
C. Apply a zinc-rich primer, epoxy intermediate coat, and acrylic urethane finish coat to the prepared surfaces.
i. Alternately, consider applying a zinc-rich primer with polysiloxane finish coat to reduce concerns with paint fumes.
This alternative would omit the epoxy and urethane coats.
Interior
1. Complete a maintenance inspection of the tank interior within the next 4- years. This next maintenance inspection should pay special attention to the advancing corrosion on the edges of the roof support structure.
Future Miscellaneous Considerations
1. Consider welding steel plates to abandon the upper shell vents (prior to any paint work and with the understanding that interior lining will be damaged).
2. Consider retrofitting the overflow pipe to include a screened air-gap.
3. Consider abandoning the floor drain and retrofitting the tank with a new flush-clean out manway.
4. Consider adding flexible couplants to the lower shell piping.
5. Repair the mechanical water level indicator if it is needed for operations.
6. Retrofit the tank with a better fall prevention system.
7. Verify that the perimeter fencing is continuous
NOTICE: This report represents the opinion of CSI Services, Inc. This report is issued in conformance with generally acceptable industry practices. While customary precautions were taken to ensure that the information gathered and presented is accurate, complete and technically correct, it is based on the information, data, time, and materials obtained and does not guarantee a leak proof tank.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo Summary
Photo 1 –Overview of Reservoir No .4
and the adjacent Pumphouse.
Photo 2 – Reservoir No. 4 - View of
roof with fields of rust. Also in view is
a CP handhole cover.
Photo 3 – Reservoir No. 4 – View of
roof with fields of rust. Also in view is
a CP handhole cover.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 4 – Reservoir No. 4 – View of
roof with fields of rust.
Photo 5 – Reservoir No. 4 - View of
roof with fields of rust. Also in view is
a CP handhole cover.
Photo 6 – Reservoir No. 4 - View of
roof CP handhole cover with
undercutting corrosion extending
from the hole.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 7 – Reservoir No. 4 – View of a
roof plate with fields of rust.
Photo 8 – Reservoir No. 4 – View of
rust developing within cracked paint.
Photo 9 – Reservoir No. 4 – View of
roof CP handhole cover with
undercutting corrosion and a conduit
connection also rusting.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 10 – Reservoir No. 4 – View of
the center roof vent with fields of rust.
The extent of the roof railing at the top
of the ladder is also in the
background.
Photo 11 – Reservoir No. 4 – Close-up
view of the grating and underlying
mesh to the center vent above.
Photo 11 - Reservoir No. 4 – View of
the roof rail adjacent to the right of the
ladder and hatch access. The rail and
the top of the water level mechanism
is also in view.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 13 – Reservoir No. 4 - View of
the roof rail adjacent to the left of the
ladder and hatch access. The bottom
of the antenna pole is also in view.
Photo 14 – Reservoir No. 4 – View of
the top of the ladder fall prevention
cage with rust and flaky paint.
Photo 15 – Reservoir No. 4 – View of
down the ladder and fall prevention
cage with rust and flaky paint.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 16 – Reservoir No. 4 – View of
the roof access hatch at the top of the
ladder with rust and flaky paint. The
lid opens outward, away from the top
of the ladder.
Photo 17 – Reservoir No. 4 – View of
some more advanced rust in the form
of scaling on the throat of the roof
access hatch.
Photo 18 – Reservoir No. 4 – View of
some more advanced rust in the form
of scaling on the throat of the roof
access hatch.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 19 – Reservoir No. 4 – Overview
of the west side of the paint on the
shell that was mostly free of any
widespread rust.
Photo 20 – Reservoir No. 4 – Overview
of the east side of the paint on the
shell that was mostly free of any
widespread rust.
Photo 21 – Reservoir No. 4 – View of
the upper portions of the overflow
pipe, water level indicator, and shell
ladder.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 21 - Reservoir No. 4 - View of
the lower portion of the water level
indicator and shell ladder within a
smaller fences area. The CP rectifier
box is also in view.
Photo 23 – Reservoir No. 4 – View of
the lower portion of the overflow pipe
that directly enters the ground, and a
possible drain vault covered with
wood planks. The paint in this area
was mostly free of rust, but did have
some flaky paint.
Photo 24 – Reservoir No. 4 – View of
the paint on the lower shell course
that typically was weathered with
some minor mechanical damage.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 25 – Reservoir No. 4 – View of
the paint on the lower shell course
that typically was weathered with
some minor mechanical damage.
Photo 26 – Reservoir No. 4 – View of a
CSI test area that reveals the film
thickness readings and poor bond
between the upper coating and red
primer.
Photo 27 – Reservoir No. 4 - View of
the typically weathered paint on the
lower shell piping.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 28 – Reservoir No. 4 – Overview
of the uni-bolt manway that had
corrosion common to its surfaces.
Photo 29 – Reservoir No. 4 - View of
the tank name plate that was located
above the manway seen in Photo 28
above.
Photo 30 – Reservoir No. 4 – View of
lower chine that had flaky paint and
rust developing on the leading edge of
the interior floor plate.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 31 – Reservoir No. 4 - View of
lower chine that had flaky paint and
rust developing on the leading edge of
the interior floor plate.
Photo 31 – Reservoir No. 4 - View of
lower chine that had flaky paint and
rust developing on the leading edge of
the interior floor plate.
Photo 33 – Reservoir No. 4 – Overview
of the opened rectifier box seen in
Photo 21 above.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 34 – Reservoir No. 4 – View the
LCD reading within the opened
rectifier box seen in Photo 33 above.
Photo 35 – Reservoir No. 4 – View of
the interior lining within the vapor
space of the tank. Some advance
corrosion is noted on the upper
portion of a tension bar.
Photo 36 – Reservoir No. 4 - View in
the foreground of a tension bar that
once corroded, but as properly
relined. The interior ladder and upper
shell in the background also appears
to be in satisfactory condition.
Final Report - Tank Paint Evaluation
Reservoir No. 4
City of San Clemente
April 23, 2023
Photo 37 – Reservoir No. 4 - View of
two connection of earthquake rods to
a rafter. The fastener noted has
severely corroded.
Photo 38 – Reservoir No. 4 - View CP
components in satisfactory condition
with the roof plate and upper shell in
the background also appearing to be
in satisfactory condition. The
unsealed upper chine has corrosion.
Photo 39 - Reservoir No. 4 - View of
the lower shell and floor that does
not appear to have any rusting
coating defects. The dark lines on the
tank bottom are from sediment that
has accumulated on floor plate weld
seams.
© Copyright CSI Services, Inc. 2004
Chart 1 - Condition Rating The table below gives a basic description of the four different categories that CSI Services, Inc. uses to provide a general depiction of the condition of each defined area of a structure. The categories are Poor, Fair, Good, or Excellent. The development of these categories is based on historical knowledge and experience of various paint and lining systems over given periods of time in certain service environments. Basically, the rating is determined based on what should be expected of the paint or lining system at that point in its life cycle. As a result, different determinations are made for maintenance inspection versus warranty inspections. A detailed description of each rating with relative consideration addressed follows:
General Description of Conditions Rating Maintenance Inspection Warranty Inspection Poor
This condition is usually prioritized for
rework in the short-term. Typically, these
surfaces have considerably more coating
defects and/or corrosion than what is
expected for the age of the system.
This condition identifies an area with
wholesale coating defects or corrosion
concerns that will typically require
significant removal and replacement of
the coatings in the area.
Fair
Typically, these surfaces have a level of
coating defects and/or corrosion that is
slightly worse than what should be
expected for the age of the system. This
condition is placed on a short-term
monitoring schedule.
This condition identifies an area with
partial coating defects or corrosion
concerns that will require significant
rework.
Good
This condition is rated for areas without
any considerable coating defects or
corrosion. These surfaces are in a
condition that is typical for the age of the
coating system.
This condition identifies areas with
coating defects or corrosion that is
typically seen in one-year warranty
inspections. Typically, only minor spot
repairs are required.
Excellent
This condition is for areas without any
considerable coating defects or corrosion.
Typically, these surfaces are in a
condition that is better than expected for
the age of the system.
This condition identified areas that
typically are in perfect condition and
require no repair work.
Copyright CSI Services, Inc. 2004
Chart 2 -Rust Grade The black and white figures below depict the standards referenced in ASTM D610 “Standard Test Method for Evaluating Degree of Rusting on Painted Surfaces.” Below each standard is a photographic depiction of each level of corrosion, as used by CSI Services, Inc. The standards depict the percentage of rust on a scale from 0 to 10, with 10 having no rust and 0 having complete rust.
Rust Grade 10 Rust Grade 9 Rust Grade 8 Rust Grade 7 Rust Grade 6 Rust Grade 5 Rust Grade 4 Rust Grade 3 Rust Grade 2 Rust Grade 1
Rust Grade 0
Rust Grade Description
10 No rusting or less than 0.01% of surface rusted
9 Minute rusting, less than 0.03% of surface rusted
8 Few isolated rust spots, less than 0.1% of surface rusted 7 Less than 0.3% of surface rusted
6 Excessive rust spots, but less than1% of surface rusted 5 Rusting to the extent of 3% of surface rusted
4 Rusting to the extent of 10% of surface rusted
3 Approximately one-sixth of the surface rusted
2 Approximately one-third of the surface rusted
1 Approximately one-half of the surface rusted
0 Approximately 100% of the surface rusted
© Copyright CSI Services, Inc. 2004
Chart 3 - Corrosion Grade The figure below depicts the photographic standards referenced by CSI Services, Inc. in the determination of the characteristics and stages of corrosion progression. This standard is used to better quantify the level of corrosion once it has progressed to Rust Grades 3, 2, 1, or 0 (see Chart 2). When applicable, CSI classifies an area as one or more of the five different Corrosion Grades. Corrosion Grades 1 through 5 are described below:
Grade Description Photo Examples
1 Light Rust - This
condition involves
relatively light colored
rust that does not
have any significant
metal loss.
2 Dark Rust -This
condition involves
relatively dark
colored, thicker rust
that is progressing
towards the next
phase, significant
metal loss.
3 Pitting - This
condition involves
isolated or
widespread deep
spot corrosion
(pitting).
4 Scale - Also known
as lamellar or
exfoliation corrosion.
The edges of the
affected area are leaf
like and resemble the
separated pages of a
wetted book.
5 Structural Loss - This
condition involves
metal loss or failure
where components
will require structural
consideration
The photos depicted are examples and were not taken on this project. © Copyright CSI Services, Inc. 2004
Chart 4 - Chalking The figure below depicts the photographic standards referenced in ASTM D4214 “Standard Test Method for Evaluating the Degree of Chalking of Exterior Paint Films,” Method D659, Method C. Generally speaking, chalking is the degradation of a paint’s binder leaving behind loose pigments as the binder reacts with the environment, primarily ultraviolet light and oxygen. Evaluating chalking is a means to measure the performance of a coating system and its life cycle projection. It is also important to quantify for consideration of future overcoating options. This test uses these pictorial standards to quantify the amount of chalking present on paint films. The depictions below represent the mount of colored chalk removed onto a cloth during the test. The scale ranges from 2 to 8 with the rating 2 having the most chalk.
Light Colored Paints
No .8 No. 6 No .4 No. 2
Dark Colored Paints
No .8 No. 6 No .4 No. 2
© Copyright CSI Services 2004
Chart 5 - Adhesion Rating The figures below depict the photographic standards and criteria referenced in ASTM D3359 “Standard Test Method for Evaluating Adhesion by Tape Test” and ASTM D6677 “Standard Test Method for Evaluating Adhesion by Knife.” Both Standards are used to assess the condition of a paint system for life-cycle projections. It is also used to evaluate an existing paint system’s ability to withstand the added stress that any overcoating strategies can create. Depending upon the thickness of the paint system, ASTM D3359 has two different test methods. The rating criteria for both standards follow:
ASTM D3359
Method A Method B
Rating Observation
Surface of X-cut from
which flaking/peeling has
occurred
Rating Percent Area
Removed
Surface of cross-cut area from
which flaking has occurred for
six parallel cuts and adhesion
range by percent
5A
No peeling or
removal None 5B 0% none
4A
Trace peeling or
removal along
incisions or their
intersection
4B Less than
5%
3A
Jagged Removal
along incisions up
to 1/16” on either
side
3B 5 – 15%
2A
Jagged removal
along most of
incisions up to 1/8”
on either side
2B 15 – 35%
1A
Removal from most
of the area of the X
under the tape 1B 35-65%
0A
Removal beyond
the area of the X 0B Greater than
65%
ASTM D6677
Rating Description
10 Fragments no larger than ” x ” can be removed with difficulty 8 Chips up to ” x ” can be removed with difficulty
6 Chips up to ” x ” can be removed with slight difficulty 4 Chips larger than ” x ” can be removed with slight pressure 2 Once coating removal is initiated by knife, it can be peeled at least ” 0 Coating can be peeled easily to length greater than ” Attn:
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Cust. Sample ID
Parameter
Sample ID Location
Method Result RL* Units Analysis Date Analyst
Matrix 3DLQW
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State Certifications
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