Industrial Sludge

Capping over exposed industrial sludge: Solutia, Bridgeport

Solutia Landfill Installation of factory assembled Dura♦Skrim® R20BV panels over exposed sludge.

Site: Solutia Bridgeport

Location: Bridgeport, NJ

Project Application: Capping over exposed industrial sludge

Project Challenges
  • Exposed sludge created a difficult installation condition
  • Fully exposed landfill cap
  • Soft exposed sludge created surface stabilization issues
  • Extreme variations in surface temperatures with minimal thermal reactivity
Project Solution

Dura♦Skrim® R20BDV

  • 20 mil scrim reinforced LLDPE liner system
  • Tensile capacity for initial sludge capping and construction operations
  • Prefabricated panels to expedite installation and minimize field seaming

Dura♦Skrim® K45BT2

  • 45 mil scrim reinforced and textured LLDPE liner system
  • Prefabricated panels to expedite installation and minimize field seaming
  • Engineered resins to provide 20 year minimum warranty
  • Reinforcement & double sided texture provides enhanced stability
  • Specialty composite design greatly reduces thermal reactions
Project Challenge

The industrial landfill site is located at the Delaware River Plant and has been in operation since 1961. Manufacturing byproducts such as plasticizers, flame retardants, and organic chemicals were disposed of within the onsite landfill and capped off. Due to the age and method of construction, stability issues created the need to contain and recap the site. The industrial sludge, which behaves hydrophillically, became exposed at the top of the site and created issues with installation and access. The capping system required for the project needed to have limited thermal expansion and contraction, capable of a minimum 20 year exposed life expectancy, high tensile strengths for ongoing surface inspections and operations, and good surface texture for those operations.

Project Solution

In order to get the project started, the exposed sludge at the surface of the cap needed to be stabilized or bridged. Attempts to chemically stabilize the sludge failed, so a bridging technique was used. The Dura♦Skrim® R20BV was used at the cap surface to cover the exposed sludge and help support surface crews while installing the final cap material. The Dura♦Skrim® R20BV was delivered to the job site in prefabricated panels that were then unfolded and installed over the exposed sludge. The outer perimeter of this liner was then trenched and buried to create a membrane capable of carrying the tensile loads created by primary capping operations. Due to the internal reinforcement of the R20BV, this initial cap was capable of safely carrying the load of the installation crews over the underlying, extremely soft industrial sludge. The next step in the capping operation included the Dura♦Skrim® K45BT2. This is a 45mil double-sided textured, scrim reinforced membrane. This would serve as the primary exposed liner and was also delivered in prefabricated panels to assist with installation operations and time. These panels ranged in size from 62’ x 140’ to 45’ x 230’. Each of these panels were delivered to the job site in a protected roll. These rolls were then moved to their predesigned location, unrolled and deployed into place. After multiple panels were deployed, they were then welded together creating a unified capping system. The new capping system, with the internally reinforced Dura♦Skrim® K45BT2, is capable of providing a 20 year warranty for exposure, exceptional performance in tensile strength for periodic monitoring and surface operations, and minimal thermal reactivity to minimize cap stresses incurred from temperature related expansion and contraction.

Placement of factory assembled Dura♦Skrim® K45BT2 panels on top of prepared platform.
Folded panel of Dura♦Skrim® K45BT2 being opened for installation.
Folded panel of Dura♦Skrim® K45BT2 being aligned for welding preparation.
Panel of Dura♦Skrim® K45BT2 being welded to adjacent panel.