Sulfur pit roof degradation mitigation
A sulfur pit that mitigates water ingress may include a concrete slab roof that comprises a first concrete slab and a second concrete slab; a polymer sealant disposed on an exterior surface of the concrete slab roof; a refractory layer disposed on an interior surface of the concrete slab roof; and at least one expansion joint located in the gap between the first concrete slab and the second concrete slab. The expansion joint may include a fiber rope disposed in the gap between the first concrete slab and the second concrete slab; a fluoroelastomer caulk located (a) in a first spacing between the fiber rope and the first concrete slab and (b) in a second spacing between the fiber rope and the second concrete slab; and a steel plate spanning the gap between the first concrete slab and the second concrete slab.
1. A system comprising:
a sulfur pit comprising a concrete structure having a concrete slab roof, wherein the concrete slab roof comprises a first concrete slab and a second concrete slab, wherein the first concrete slab and the second concrete slab are located adjacent to each other and are coplanar, and wherein there is a gap between the first concrete slab and the second concrete slab;
a polymer sealant disposed on an exterior surface of the concrete slab roof, wherein the exterior surface is directed toward an exterior of the sulfur pit, and wherein the exterior surface comprises exterior faces of the first concrete slab and the second concrete slab;
a refractory layer disposed on an interior surface of the concrete slab roof, wherein the interior surface is directed toward an interior of the sulfur pit, and wherein the interior surface comprises interior faces of the first concrete slab and the second concrete slab; and
at least one expansion joint located in the gap between the first concrete slab and the second concrete slab, wherein the at least one expansion joint seals the gap between the first concrete slab and the second concrete slab,
wherein the polymer sealant is coextensively positioned over an entirety of the exterior surface of the concrete slab roof and the expansion joint, and the refractory layer is coextensively positioned over an entirety of the interior surface of the concrete slab roof and the expansion joint.
2. The system of claim 1 , wherein the polymer sealant comprises a first exterior layer and a second exterior layer, wherein the first exterior layer comprises an epoxy resin, and wherein the second exterior layer comprises a polyurethane elastomer.
3. The system of claim 1 , wherein the polymer sealant further comprises a plurality of silica nanoparticles.
4. The system of claim 1 , wherein the polymer sealant further comprises a plurality of fibers, a plurality of particles, or any combination thereof.
5. The system of claim 1 , wherein the refractory layer comprises a first interior layer and a second interior layer, wherein the first interior layer comprises an asphalt layer, and wherein the second interior layer comprises a potassium-silicate compound.
6. The system of claim 1 , wherein the at least one expansion joint has a width from 10 mm to 100 mm.
7. The system of claim 1 , further comprising at least one anchor, wherein the at least one anchor joins the refractory layer to the interior surface of the concrete slab roof.
8. The system of claim 7 , wherein the at least one anchor comprises a steel anchor.
9. The system of claim 1 , wherein the at least one expansion joint comprises:
a fiber rope, wherein the fiber rope is disposed in the gap between the first concrete slab and the second concrete slab;
a fluoroelastomer caulk, wherein the fluoroelastomer caulk is located in a first spacing between the fiber rope and the first concrete slab, and wherein the fluoroelastomer caulk is located in a second spacing between the fiber rope and the second concrete slab; and
a steel plate spanning the gap between the first concrete slab and the second concrete slab, wherein the steel plate is anchored by a first fastener to the first concrete slab, and wherein the steel plate is anchored by a second fastener to the second concrete slab.
10. The system of claim 8 , wherein the first fastener and the second fastener comprise: a bolt, a screw, a nail, a staple, or any combination thereof.
11. A method comprising:
providing a sulfur pit comprising a concrete structure having a concrete slab roof, wherein the concrete slab roof comprises a first concrete slab and a second concrete slab, wherein the first concrete slab and the second concrete slab are located adjacent to each other and are coplanar, and wherein there is a gap between the first concrete slab and the second concrete slab;
disposing a polymer sealant on an exterior surface of the concrete slab roof, wherein the exterior surface is directed toward an exterior of the sulfur pit, and wherein the exterior surface comprises exterior faces of the first concrete slab and the second concrete slab;
disposing a refractory layer on an interior surface of the concrete slab roof, wherein the interior surface is directed toward an interior of the sulfur pit, and wherein the interior surface comprises interior faces of the first concrete slab and the second concrete slab; and
affixing at least one expansion joint in the gap between the first concrete slab and the second concrete slab to seal said gap between the first concrete slab and the second concrete slab,
wherein the polymer sealant is coextensively positioned over an entirety of the exterior surface of the concrete slab roof and the expansion joint, and the refractory layer is coextensively positioned over an entirety of the interior surface of the concrete slab roof and the expansion joint.
12. The method of claim 11 , wherein the polymer sealant comprises a first exterior layer and a second exterior layer, wherein the first exterior layer comprises an epoxy resin, and wherein the second exterior layer comprises a polyurethane elastomer.
13. The method of claim 11 , wherein the refractory layer comprises a first interior layer and a second interior layer, wherein the first interior layer comprises an asphalt layer, and wherein the second interior layer comprises a potassium-silicate compound.
14. The method of claim 11 , further comprising at least one anchor, wherein the at least one anchor joins the refractory layer to the interior surface of the concrete slab roof.
15. The method of claim 11 , wherein the at least one expansion joint comprises:
a fiber rope, wherein the fiber rope is disposed in the gap between the first concrete slab and the second concrete slab;
a fluoroelastomer caulk, wherein the fluoroelastomer caulk is located in a first spacing between the fiber rope and the first concrete slab, and wherein the fluoroelastomer caulk is located in a second spacing between the fiber rope and the second concrete slab; and
a steel plate spanning the gap between the first concrete slab and the second concrete slab, wherein the steel plate is anchored by a first fastener to the first concrete slab, and wherein the steel plate is anchored by a second fastener to the second concrete slab.