TL:DR (Didn’t post the entire article it is quite long)

In liquid-bearing concrete structures, joints are where protective linings fail first. A monolithic film is asked to span a moving gap and stay bonded to both sides through thermal swings, settlement, hydrostatic loads, and start-stop operations. Over thousands of cycles, stress concentrates at the arris; micro-pinhole strings and edge-shear accumulate until the first callbacks show up — always at joints

Why Joints Beat Monolithic Films (Quick Mechanics)

Differential movement. Adjacent pours and wall-to-slab interfaces move independently. Typical thermal expansion alone in a 100-ft. wall across a 20° F swing produces approximately 1/8 in. of movement. Repeat that across seasonal and operational cycles and fatigue is inevitable — especially where you've got foundation settlement, soft soils, or structures built on expansive clay.

Stress concentration. Continuous films focus strain at sharp edges where small flaws become crack starters. Even a microscopic imperfection in surface prep becomes the failure point when subjected to thousands of movement cycles.

Fatigue and adhesion limits. Even high-elongation elastomers fatigue under cyclic shear at joint interfaces. Rigid films split or debond. The coating chemistry might be excellent, but physics wins every time when movement concentrates at a single point.

The Joint-Integrated Detail (What Actually Works)

Instead of trying to glue two moving parts together and hoping adhesion holds, a joint-integrated detail creates a controlled chase and bridges it with reinforcement that's fully wetted with resin and tied into the field coating. Movement happens beneath the lining; the composite bridge carries strain without pulling the coating apart.

ICRI 310.2R (Concrete surface profile guidance) SSPC-SP13/NACE No. 6 (Surface preparation of concrete) Moisture testing:

ASTM F2170 (In-situ concrete relative humidity) ASTM F1869 (Moisture vapor emission rate) ASTM F3010 (Moisture vapor barrier qualification) Quality control:

ASTM D7234 (Pull-off adhesion on concrete) ASTM D5162 (Holiday/continuity testing) ASTM D6132 (Ultrasonic DFT measurement on non-metallic substrates) ASTM D4138 (Destructive DFT measurement) Disinfection (potable water):

AWWA C652 (Disinfection of water storage facilities) Acceptance and Documentation Checklist

□ Record ASTM F2170 relative humidity readings □ Record ASTM F1869 MVER if specified □ Confirm readings within primer manufacturer limits □ Document environmental conditions during testing

□ Note target ICRI CSP (typically 3-5 for elastomeric systems) □ Capture comparator chip photos showing achieved profile □ Document areas requiring additional prep or repair Adhesion testing:

□ Map pull locations per ASTM D7234 (minimum 3 pulls per 500-1,000 sq ft) □ Add targeted pulls at joint zones and transitions □ Log failure mode (concrete failure = pass; coating delamination = investigate) □ Photo-document all test locations and results

□ In-process wet film checks with gauge □ Final DFT by ASTM D6132 (ultrasonic preferred) or D4138 where allowed □ Record readings by zone (field areas vs. joint zones) □ Verify minimum DFT achieved across entire surface

□ Select test method: spark or wet sponge per ASTM D5162 □ Set voltage per standard chart based on actual installed DFT □ Note electrode type and travel speed □ Mark and repair all detected holidays □ Retest repairs and document passing results Handover packet:

□ Surface prep before/after photos by area □ Complete WFT/DFT logs organized by zone □ Cure time verification records □ Adhesion test map with all results □ Holiday testing report including repairs □ Environmental monitoring logs (temp, RH, dew point) □ For potable systems: AWWA C652 disinfection certificate

Fantastic article about the design and application of concrete joints!! Some of the pitfalls (not using enough coating due reinforcement) that leads to failures was quite interesting. I never had the privilege to inspect a concrete job but it is nice to know what to look for if I ever have to.