Secondary Containment Panels and Process for Making and Installing Same

Abstract

A method of manufacturing a plurality of secondary containment panels and assembling and installing the panels in a secondary containment system of an above-ground liquid storage tank or other retention facility includes forming a plurality of flexible substrate pieces. A liquid impermeable coating is applied to the upper surface of each piece such that an edge segment of the piece remains uncoated. The coating is applied to the substrate piece in an indoor enclosure using a computer controlled robotic sprayer that applies a uniform coating. A system for coating secondary containment panels. An apparatus for spraying a coating on secondary containment panels. The apparatus may be computer controlled and operate automatically to coat the surface of the panel.

1 . A system comprising:
 a computer controlled robotic sprayer housed within a structure;   a coating supply source coupled to the sprayer;   wherein the robotic sprayer comprises a nozzle, and wherein said nozzle points in a generally downward position;   wherein the robotic sprayer sprays the coating in a reciprocating pattern;   a substrate located below the robotic sprayer, wherein said substrate is moveable relative to said robotic sprayer.   
     
     
         2 . The system of  claim 1  wherein said structure comprises an environmentally controlled structure. 
     
     
         3 . The system of  claim 1  wherein said substrate is located horizontally below the robotic sprayer. 
     
     
         4 . The system of  claim 1  wherein when the computer controlled robotic sprayer is activated, the sprayer sprays a determined quantity of coating across the width of the substrate, and wherein the robotic sprayer traverses laterally across the width of the substrate, and wherein the substrate comprises a geotextile fabric. 
     
     
         5 . The system of  claim 1  wherein the substrate travels longitudinally relative to the robotic sprayer. 
     
     
         6 . The system of  claim 1  wherein the nozzle is located between about 3 and 4 feet above said below substrate. 
     
     
         7 . The system of  claim 1  wherein said robotic sprayer is coupled to a carriage, and wherein the robotic sprayer and carriage are powered by at least one motor, and wherein the sprayer extends over a width of a substrate located below said robotic sprayer, wherein the sprayer traverses laterally across the width of the substrate, and wherein the substrate comprises a geotextile fabric. 
     
     
         8 . The system of  claim 7  wherein the substrate travels longitudinally relative to the robotic sprayer. 
     
     
         9 . A system comprising:
 a computer controlled robotic sprayer housed within an environmentally controlled structure;   wherein the computer controlled robotic sprayer is laterally traversable;   wherein the sprayer comprises a nozzle;   a coating supply source coupled to the sprayer; and wherein the robotic sprayer is located above a flat surface;   a substrate located below the robotic sprayer, and wherein when the computer controlled robotic sprayer is activated, the nozzle sprays a determined quantity of coating across the width of the substrate.   
     
     
         10 . The system of  claim 9  wherein said substrate is moveable. 
     
     
         11 . The system of  claim 9  wherein said robotic sprayer is coupled to a carriage, and wherein the robotic sprayer and carriage are powered by at least one motor, and wherein the sprayer extends over a width of a substrate located below said robotic sprayer, wherein the sprayer traverses laterally across the width of the substrate, and wherein the substrate comprises a geotextile fabric. 
     
     
         12 . The system of  claim 9  wherein the coating supply source provides a coating comprising polyurea to the robotic sprayer. 
     
     
         13 . A system comprising:
 a robotic sprayer housed within a structure;   a coating supply source coupled to the sprayer;   a substrate located below the robotic sprayer, wherein the substrate comprises a geotextile fabric,   wherein the robotic sprayer sprays the coating in a reciprocating pattern;   wherein the robotic sprayer comprises a nozzle.   
     
     
         14 . The system of  claim 13  wherein said structure is indoor. 
     
     
         15 . The system of  claim 13  wherein the coating supply source provides a coating comprising polyurea to the robotic sprayer. 
     
     
         16 . The system of  claim 15  wherein said substrate is flat underneath the robotic sprayer, and wherein said substrate is moveable relative to said robotic sprayer. 
     
     
         17 . The system of  claim 15  wherein said nozzle is located about 3 feet above said substrate. 
     
     
         18 . The system of  claim 13  wherein said robotic sprayer comprises spraying a slip-resistant stippled surface.