Method for manufacturing a secondary containment liner system

1. A method of assembling a secondary containment liner system, said method comprising:

providing liquid impermeable first and second sheet components;

attaching a first substrate element to a leading edge of said first sheet component such that said first substrate element extends outwardly from said leading edge of said first sheet component;

attaching a second substrate element to a second leading edge of said second sheet component such that said second substrate element extends outwardly from said second leading edge of said second sheet component;

overlapping said first and second substrate elements; and

applying a liquid impermeable coating material to said overlapping first and second substrate elements to sealably bond the overlapping first and second substrate elements and form a liquid impermeable strip between said liquid impermeable first and second sheet components.

2. The method of claim 1 including the step of providing impermeable sheet components that are uncoated.

3. The method of claim 1 including the step of applying at least one of polyurea and polyurethane to the overlapped first and second substrate components to sealably bond said first and second substrate components together.

4. The method of claim 1 in which said substrate elements includes a material for absorbing and supporting the coating material.

5. The method of claim 1 further including the step of attaching a third substrate element to a third leading edge of at least one of said first and second sheet components, overlapping said third substrate element with a penetration structure of a primary containment facility and adhesively securing said third substrate element to the penetration structure.

6. The method of claim 5 in which said penetration structure is selected from the group consisting of a containment tank, a pipe structure and a ring wall.

7. The method of claim 5 including the step of applying at least one of polyurea and polyurethane to the overlapped first and second substrate components to sealably bond said first and second substrate components together and applying at least one of polyurea and polyurethane to said third substrate element to sealably bond said third substrate element to said penetration structure.

8. The method of claim 5 in which said substrate elements include a material for absorbing and supporting the coating material.

9. The method of claim 1 further including the step of attaching a plurality of substrate elements to corresponding leading edges of said first sheet component such that each of said plurality of substrate elements extends outwardly from a respective corresponding leading edge of said sheet component, overlapping each of said plurality of substrate elements with a complementary substrate element attached to and extending from a corresponding second leading edge of an adjacent sheet component, and applying a liquid impermeable coating material to each pair of overlapping substrate elements to form a liquid impermeable strip between said first sheet component and each adjacent sheet component.

10. A method of assembling a secondary containment liner system comprising:

providing an impermeable, uncoated sheet component adjacent to and extending outwardly from a primary containment facility;

attaching a substrate element to a leading edge of said sheet component such that said substrate element extends outwardly from said leading edge of said sheet component;

applying a curable liquid impermeable coating material to said substrate element;

overlapping said substrate element with a penetration structure of said primary containment facility; and adhesively securing said substrate element to said penetration structure.

11. The method of claim 10 further including the step of providing uncoated, liquid impermeable sheet components.

12. The method of claim 10 in which said substrate element includes a material for absorbing and supporting the coating material.

13. The method of claim 10 in which said penetration structure is selected from the group consisting of a containment tank, a pipe structure and a ring wall.

14. A method of constructing a secondary containment system about a primary containment facility, said method comprising:

surrounding the containment facility with a berm that defines a spill retention basin between the containment facility and the berm;

juxtaposing a plurality of adjacent impermeable sheets to extend across the spill retention basin between the primary containment facility and the berm;

interconnecting an adjacent pair of sheet components by attaching to a first one of said adjacent sheet components a first substrate element that extends outwardly from a leading edge of said first sheet component, attaching to a second leading edge of a second one of said adjacent sheet components a second substrate element that extends outwardly from said second leading edge of said second sheet component, overlapping said first and second substrate elements and applying a liquid impermeable coating material to the overlapping substrate elements to bond the substrate elements and form a liquid impermeable strip between the adjacent first and second sheet components;

attaching a third leading edge of at least one of said adjacent sheet components to a penetration structure of the primary containment facility by attaching a third substrate element to said third leading edge such that said third substrate element extends from said third leading edge, overlapping the third substrate element with a penetration structure of the primary containment facility and adhesively securing the third substrate element to the penetration structure, whereby the impermeable sheet components are interconnected together and attached to the penetration structure of the primary containment facility to form a liquid impermeable liner extending across the spill retention basin between the berm and the primary containment facility.

15. A method of assembling a liner in a secondary containment system, said method comprising:

providing a liner component that includes an uncoated, liquid impermeable sheet and a fibrous backing strip attached to a leading edge of said sheet for absorbing and supporting a curable liquid impermeable coating;

applying a curable liquid impermeable coating to at least one of said fibrous backing strip and an adjoining second fibrous backing strip attached to a second leading edge of a second uncoated, liquid impermeable sheet of a second liner component;

interengaging said first and second fibrous backing strips to adhere said fibrous backing strips together; and

allowing said coating to cure such that said first liner component is sealingly bonded to said second liner component.

16. A method of assembling a liner in a secondary containment system, said method comprising:

providing a first liner component that includes an uncoated, liquid impermeable sheet and a fibrous backing strip secured to and generally aligned with a leading edge of said first sheet for absorbing and supporting a curable liquid impermeable coating;

providing a second liner component that includes an uncoated, liquid impermeable second sheet and a second fibrous backing strip secured to and generally aligned with a second leading edge of said second sheet for absorbing and supporting a curable liquid impermeable coating;

providing a fabric element for extending across said first and second fibrous backing strips, said fabric element for absorbing and supporting a curable liquid impermeable coating;

applying a curable liquid impermeable coating to at least one of said fibrous backing strips and said fabric element;

interengaging said fabric element with said first and second fibrous backing strips to adhere said first fibrous backing strips to said second fibrous backing strip; and

allowing said coating to cure such that said first liner component is sealingly bonded to said second liner component.

17. A method of assembling a liner in a secondary containment system, said method comprising:

providing a liner component that includes an uncoated, liquid impermeable sheet and a fibrous element attached to and extending from a leading edge of said sheet for absorbing and supporting a curable liquid impermeable coating;

applying a curable liquid impermeable coating to at least one of the fibrous element and a penetration structure of the secondary containment system;

interengaging said fibrous element and the penetration structure of the secondary containment system to adhere the fibrous element to the penetration structure and

allowing said coating to cure such that said liner component is sealingly bonded to the penetration structure.

18. The method of claim 17 in which said fibrous element includes a backing strip secured to and generally aligned with an edge of the sheet and a fabric piece attached to the backing strip and extending beyond a leading edge of the sheet for engaging the penetration structure.