Alpha Spill Control Barrier System User Manual

Alpha Industrial Power

Spill Control Barrier System

Installation Manual

Battery Acid Spill ControlBarrier

with Acidsafe Floor Coating

Battery AcidSpillControlBarrier
without AcidsafeFloor Coating

AlphaIndustrial Power

1075Satellite Blvd,Suite100 678-475-3995
Suwanee, GA30024 800-996-6104

www.alpha.com

Alpha Industrial Power Spill Control Barrier System

Spill Control Barrier System

Installation Manual

TABLEOFCONTENTS

1. Introduction .......................................................................... 1

2. Safety Precautions............................................................... 2

3. Initial Conditions .................................................................. 4

4. Floor Preparation................................................................. 5

5. Barrier Installation................................................................. 7

6. Coating Application............................................................... 12

7. Leak Test ............................................................................. 14

8. Coating Maintenance........................................................... 15

9. MSDS Section...................................................................... 16

Installation Manual Page 1 of 25

Alpha Industrial Power Spill Control Barrier System

1. Introduction

1.1 The Battery Acid Spill Control Barrier without floor coating is intended to
contain battery electrolyte in the event of a spill or leak from a stationary
lead-acid battery. The Spill Control Barrier surrounds the battery rack with a
4 inch steel enclosure. It is bonded permanently to the floor with Acidsafe
Adhesive Gel and sealed against leakage. The Battery Acid Spill Control
Barrier with floor coating also includes Acidsafe Floor Coating, which covers
the entire floor surface within the enclosureandprotectsthefloor fromthe
corrosive effects of batteryacid. Both theCoating and Adhesive are based
on modified novolac epoxy resins with polyaminecuratives andhave been
tested to be impervious to 70%sulfuricacid in continuous immersion and up to
98% sulfuric acid in splash and spill exposure. The system may be installed
around existing battery racks without removal of the batteries and without
interruption of facility operations.

1.2 The highly adaptable design of the system allows configuration to suit a
wide range of battery room layouts. This manual covers all of the procedures
necessary in most anticipated battery room applications. If a specific
application is encountered that is not addressed in this manual, contact
Alpha Industrial Power at 678-475-3995 for additional information of
supplementary procedures

1.3 Neutra-Mats (part number 5NMB0010) inside the containment area absorb
and neutralize the acid immediately upon exposure thus greatly reducing the
risk of personal injury and structural damage or contamination. The mats are
placed side by side to completely cover the floor beneath the racks. A single
Neutra-Mat will fully absorb and neutralize one quart of battery electrolyte (pH
between 7.0- 9.0). Each individual Neutra-Mat may be quickly and easily
replaced as necessary. Additionally, Neutra-Mats turn pink upon exposure to
acid, indicating a leak and the needforreplacement. If Neutra-Matswerenot
ordered for this installation, they may be obtained from Alpha Industrial
Power.

1.4 Despite the Spill Control Barrier and Coating’s strength and durability, failure
to conscientiously follow these instructions may result in inadequate
coverage, performance,or protection.Carefullyread and understand the entire
instructionmanual before beginning assembly.

Installation Manual Page 2 of 25

Alpha Industrial Power Spill Control Barrier System

2.SafetyPrecautions

2.1 Examine all shipping containers for signs of external damage. Also look for
indications of coating spillage during shipment. In the event that coating
material has been spilled, consult the Material Safety Data Sheet for spill
handling instructions and personal protective equipment requirements.

2.2 Make note of any damage on the bill of lading before signing for delivery.

If system components have been damaged or lost in transit, contact the
shippingcarrier for instructions concerning filing a claim.

2.3 Wear steel toed shoes and safety glasses when assembling the Spill

Control Barrier.

2.4 Wear chemical resistant gloves and safety goggles when handling

Adhesive, Coating or Joint/Crack Filler. In areas where ventilation is
insufficient, a respirator may also be required. Read the Material Safety Data
Sheets supplied with this kit and be familiar with the safety precautions listed
therein.

2.5 Observe and obey all caution notes contained in the following instructions.

Installation Manual Page 3 of 25

Alpha Industrial Power Spill Control Barrier System

Figure 3.1 – Spill Control Barrier Components

1. B arr i er Stri p s

2. S p lice P l a tes

3. C o rner P l a te

4. Ass embly Hardw are

5. Acidsafe Coating (Part A) – floor coating version only

6. Acidsafe Coating (Part B) – floor coating version only

7. Acids afe Adh esive

Installation Manual Page 4 of 25

Alpha Industrial Power Spill Control Barrier System

3. Initial Conditions

3.1 For maximum effectiveness of the Spill Control Barrier, the floor surface
should be flat, smooth and reasonably level. An uneven surface can
cause gaps between the Spill Control Barrier and the floor, which may
require additional Adhesive during final assembly. Unlevel or sloped floors
may require additional Coating to achieve minimum film thickness.

3.2 Permanent floor coverings such as vinyl, linoleum, composite or asbestos tiles
will not affect the ability of the Spill Control Barrier or Acidsafe Floor Coatings to
contain acid spills, provided that the coverings are in good condition and
securelyfastenedto the floor. Loose or broken tilesshould be removed and voids
filled using Joint/Crack Filler Kit (part number 5CFK0001).

CAUTION:

All asbestos handling precautions should be observed when handling loose
or broken asbestos tiles, including respiratory protection, protective clothing
and specialized disposal. Consult with the local authority having
jurisdiction for asbestos abatement requirements.

3.3 Concrete should be completely dry and properly cured (minimum of 28
days after poured). Concrete slabs installed on or below grade or otherwise
exposed to weather may transmit water vapor, causing pinholes in the floor
coating during cure. Evening (after 7 PM) is the most suitable time of day for a
ground-floor installation as the effects of concrete off-gassing will be
minimized.

3.4 Failure to properly clean and prepare the surface of the floor prior to applying
the Adhesive and Coating can cause adhesion failure or degraded chemical
resistance over time. Appropriate floor cleaning and other surface preparatory
procedures are described in Section 4.

3.5 Local amb ien t a ir temp era ture mu st be grea ter tha n 5 0˚F when ap plying

and curing the Adhesive and Coating materials. As ambient air
temperature decreases, the time necessary to set and cure the Acidsafe

Ad hesive and Co ating incr ease s. Cold co nditio ns (bel ow 50˚F) will also

impair the Coating’s application characteristics.

Installation Manual Page 5 of 25

Alpha Industrial Power Spill Control Barrier System

3.6 The following tools and supplies are recommended for a quick and
thorough Barrier installation:

7/16 inch box end or combination wrench
putty knife

tape measure
several sheets of sandpaper, 100 grit
roll of 1 inch masking tape
goggles,chemicalresistantgloves andrespirator (asneeded)for
installers’ paper towels or shop rags

rubbing alcohol

3.6.1 Additional supplies needed for Spill Barrier with floor coating version

only:
small metal ruler with 1/64” increments or wet film thickness gauge.

The Coating Installation standard Tool Kit (part number
5BNK0001) contains: small rotary stirring tool, two v-notch trowels,
four v-notch spreaders, onemaskingtape, twobrushes,two gloves,
tworags, twoputty knives, one 3-piece extension, one 1-1/2 inch
spiked pin roller, one pair goggles, and two sheets sandpaper.
(Other kits available upon request)

4.FloorPreparation

4.1 The installer or site/equipment engineer must ensure that sufficient aisle space
will remain once the Barriers have been installed. There should be a minimum
of 30 inches between Barriers. Aisle spacing at the end of each rack may be as
little as 24 inches, providing no conflict exists with battery maintenance
requirements. The aisle spacing,includingthe space between the surrounding
Barriers, should be sufficienttopermitallrequired maintenance (includingbattery
installationandremoval). SeetheNationalElectric Codeorcontactthelocalauthority
having jurisdiction for further clarification regarding aisle clearances.

4.2 After clearances have been verified, locate and mark the outline of the
Barrierusing the Barrier’s dimensionsand a tape measure.TheBarriershould

becentered around the rack with at least 1 inch clearance in all directions
to meet 1995 Uniform Fire Code article 64 requirements.

Installation Manual Page 6 of 25

Alpha Industrial Power Spill Control Barrier System

4.3 Completely clean and prepare the portion of flooring which will have Adhesive
or Coating applied during installation. For Barrier System versions without
floor coating, this area is a strip approximately 3 inches wide inside the
outline of the Barrier perimeter. For Barrier System versions with floor
coating, this includes the entire area inside the outline of the Barrier
perimeter. Prepare the flooring according to the following guidelines.

All Floor Types: Remove all oil, grease, dirt, efflorescence, laitance,
chemicals, hardeners,curing membranes,wax, previouslyapplied coatings or
othersurfacecontainments. Floors may be cleaned with an alkaline detergent
dissolvedin hot water, scrubbed with a non-metallic stripping pad and rinsed
several times. Alternatively, clean using steam, water (low pressure), air
blast, vacuum, and broom cleaning methods as described in ASTM D 4258
and SSPC-SP-1.

Concrete Floors: Roughen surface by abrading or etching. Concrete may
be etched with a 20% phosphoric acid solution, mechanically scrubbed, and
rinsed with a neutralizing solution (2 lb. Sodium bicarbonate and 1 gal.
Water) and followed by a clean water rinse. Alternatively, abrade by steel
shot blasting, sandblasting, water jetting with abrasive, power tool cleaning, or
scarifying as described in ASTM D 4258 and NACE RP-01-72.

4.4 Perform a check for cleanliness by rubbing the floor with a clean, white cloth.
If the cloth appears dirty, perform Step 4.3 again. Also check surface

preparation by performing the following ‘water-break’ test: pour a small
amount of clean water onto the surface and observe. If water evenly wets
the surface, the cleaning is adequate.If the water forms beads on the
surface,performStep 4.3 again. Allow surfaces to completely dry before
applying Adhesive or Coating.

4.5 Use 100 grit aluminum oxide or silicon carbide sandpaper to lightly sand the
underside of the Barrier Strips and the mating surfaces of the connector
plates. Wipe all sanding debris from the Barrier Strips with a clean rag.

4.6 Inspect the floor inside the containment area for any progressive cracks
greater than 1/8 inch in width, as well as for control/expansion joints. Such
surface defects must be repaired or filled with a Joint/Crack Filler before
progressing any further with the Spill Control System installation. Smaller
defects may be filled using Adhesive and a putty knife. A Joint/Crack Filler
Kit is available from Alpha Industrial Power.

Installation Manual Page 7 of 25

Alpha Industrial Power Spill Control Barrier System

Figure 5.1 – Mixing the Adhesive

Figure 5.2 – Preparing Mixing Bag for Application

5. Barrier Installation

5.1 Lay out the Barrier Strips on the floor around the battery stand location in the
order demonstrated in Figure 3.1 and lightly bolt the pieces together using
carriage bolts, washers, nuts and the appropriate connector plates. Position
the barrier around the batterystand location to provide equal clearances on all
sides between the battery stand and the barrier. Note that the horizontal
flange on all of the barrier strips faces the battery stand (Figure 3.1). This
orientation is important both for barrier clearance and liquid-tight integrity.

CAUTION:

Barrier strips and connectorsareconstructed fromsteelandcoatedwith an acid
resistant epoxy. These strips should be handled with care near all electric
power sources. Contact with an electrical source could result in severe shock
or death. This product should only be installed by trained professionals
familiar with the electrical hazards of high energy DC back up power systems.

Installation Manual Page 8 of 25