Secondary containment panels and process for making and installing same

1. A method of environmentally controlled manufacture and on-site assembly of a plurality of secondary containment panels for use in a secondary containment system, said method comprising:

forming a plurality of flexible substrate pieces;

spraying a liquid impermeable coating onto an upper surface region of each said piece at a sufficient distance from said piece to produce a stippled, slip-resistant texture across said region of said piece onto which said coating is sprayed, said coating being sprayed onto said substrate piece in an environmentally controlled enclosure;

allowing each said substrate piece to cure in said environmentally controlled enclosure, said coating being sprayed onto said upper surface region of said substrate piece in sufficient thickness to render said sprayed region of said substrate piece impermeable to the passage of liquid without requiring subsequent on-site application of additional coating onto said sprayed region;

delivering said coated substrate pieces having respective liquid impermeable sprayed regions from the environmentally controlled enclosure to the site of a containment system;

extending said coated substrate pieces across the ground and juxtaposing at least one pair of said pieces relative to one another such that a first one of said pieces overlaps a second said piece to form a seam; and

applying an adhesive substance to said seam to fasten said first and second pieces together and seal said seam.

2. The method of claim 1 in which said substrate pieces are extended across the ground without interposing adhesive material between respective lower surfaces of said pieces and the ground.

3. The method of claim 1 in which said adhesive substance comprises a liquid impermeable material that is allowed to cure to render said seam impervious to the passage of liquid.

4. The method of claim 1 in which said liquid impermeable coating is sprayed onto said upper surface region of said substrate piece such that an edge segment of said piece remains uncoated.

5. The method of claim 1 in which said coating is sprayed onto the upper side of said substrate in an indoor enclosure wherein wind and rain are substantially restricted from dissipating or otherwise affecting the coating as it is sprayed.

6. The method of claim 4 in which said adhesive substance is introduced between said lower surface of said first piece and said uncoated edge segment of said second piece and the overlapping pieces are pressed together.

7. The method of claim 1 in which said adhesive substance is applied across said seam and to the upper surfaces of each of said first and second pieces.

8. The method of claim 1 in which said adhesive substance includes polyurea coating.

9. The method of claim 1 in which said adhesive substance includes a two sided tape interposed between said overlapping pieces.

10. The method of claim 1 wherein said substrate piece includes a geotextile fabric.

11. The method of claim 1 wherein the said impermeable coating includes polyurea.

12. The method of claim 1 in which application of said adhesive is limited to a region extending along and proximate to said seam.

13. The method of claim 1 in which said adhesive includes a liquid impermeable coating that is introduced between said overlapping pieces and sprayed across an upper surface of said seam in an elongate strip that generally follows said seam.

14. A method for manufacturing and installing a secondary containment system for a tank or other liquid retention site, said method comprising:

forming a berm that surrounds the tank or other liquid retention site to define a spill retention basin between the tank or other liquid retention site and the berm;

forming a plurality of flexible substrate pieces;

spraying a liquid impermeable coating onto an upper surface region of each said piece at a sufficient distance from said piece to produce a stippled, slip-resistant texture across said region of said piece onto which said coating is sprayed, said coating being sprayed onto said substrate piece in an environmentally controlled enclosure;

allowing each said substrate piece to cure in said environmentally controlled enclosure, said coating being sprayed onto said upper surface region of said substrate piece in sufficient thickness to render said sprayed region of said substrate piece impermeable to the passage of liquid without requiring subsequent on-site application of additional coating material onto said sprayed region;

delivering said coated substrate pieces to the site of the secondary containment system;

extending said coated pieces across the spill retention basin and juxtaposing adjoining pairs of said pieces relative to one another such that a first one of said pieces overlaps a second said piece to form a seam; and

applying an adhesive substance to said seam to fasten said first and second pieces together and seal said seam.

15. The method of claim 14 in which said adhesive substance is liquid impermeable to render said seam impervious to the passage of liquid there through.

16. The method of claim 14 in which said sprayed regions of said substrate pieces are impervious to the passage of liquid there through and into the underlying spill retention basin without requiring the application of any additional liquid impermeable coating onto said sprayed regions of said substrate pieces.

17. The method of claim 14 in which said substrate pieces are extended across said spill retention basin without interposing adhesive material between respective lower surfaces of said pieces and the spill retention basin.

18. The method of claim 14 in which said adhesive includes a liquid impermeable coating that is introduced between said overlapping pieces and sprayed across an upper surface of said seam in an elongate strip that generally follows said seam.

19. The method of claim 14 in which said liquid impermeable coating is sprayed robotically onto each substrate piece.