Tank Internal Chemical Corrosion Protection

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Internal surface of this Sulphur Solution Storage Tank is constantly in contact with the medium and the dome of the tank having continuous contact of the vapours generated inside the tank. On a account of such operating conditions prevailed inside the tank, the surface internally has been corroded very severely which lead to loss of metal and reduction in shell thickness of the tank. Looking at the desired needs of protection, ProCoat Coatings were the best choice that deemed fit for this application.

Initially the surface was neutralized by means of water washing and detergent cleaned, scrubbing the surface to eliminate the deposited traces of corrosion causing elements. After the completion of this task relevant test methods were carried out over the surface to checks for the presence of chemical and corrosion causing agents over the surface.

The surface was blast cleaned once & water washed again to remove further remaining traces of chemical content which was cross-checked using relevant test methods. Second round of blast cleaning was carried out using copper slag abrasive media to Sa 2.5 surface profile to near white metal finish ensuring the necessary surface roughness.

Over the prepared surface, ProCoat coating was applied using spatulas & synthetic rollers in order to deposit the material all over the surface uniformly. Two different coatings systems were incorporated for this application, an high end ProCoat Coating system was applied to the tank bottom surface which not only provides resistance to corrosion but also the endurance to the acting load of the liquid which is being stored inside the tank. Rest of the tank internal surface was coated using ProCoat’s chemical resistant coating system to offer the best protection the metal surface from falling prey to the working corrosive medium.

Quality measurement checks in terms of the coating thickness being deposited over the surface was done using the Elcometer WFT Comb. Once the coating was cured, Dry Film Thickness was measured using the Elcometer DFT Gauge & examined with Holiday Spark Tester to ensure firm coating integrity. To execute the entire task qualitatively inside this 11 meter tall tank, abiding to the safe applications methods, a tailor made scaffolding system was installed to access all parts of the tank surface which has been coated with ProCoat Advanced Polymer Coating System to establish the righteous protection to the metal surface.

Tank Internal Corrosion & Abrasion Protection Lining

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These newly fabricated mild steel tanks were intended for storing sludge which comes out after the operational process inside scrubber vessel of the steel making industry. The sludge which is a thick fluid with solid particles along with high temperature that has an abrading & corroding action over the internal surface of this mild steel tank. Keeping in view the proven performance of ProCoat Coatings & Quality Application Methods in safe-guarding the internal surface of various equipments, the client chose ProCoat Coating Systems entrusting the reliability and durability showcased.

Initially the protruding weld beads were removed using the a grinding machine making the surface even. Thereupon the surface was blast cleaned using chilled iron grit to ensure the desired surface roughness of an average 100+ microns to Sa 3 Swedish Standards, prior to coating application. In order not to expose the blast cleaned surface to open air atmospheric conditions of the plant, portion by portion of the tank was addressed by blast cleaning and immediately followed up with coating works over these 11 meter tall tanks. To access the entire surface of the tank ladders and suspended platforms were utilised abiding to all the safety norms. The coating was checked for thickness levels using Elcometer WFT Gauge intermittently and cross-verified using Elcometer DFT Gauge on curing. Holiday Spark Testing was carried out over the entire surface of tank to make sure rigid coating integrity without any flaws.


After completion of the coating works, the tank was put into operations for storing the sludge. These tanks were coated in the year 2011 and since then a convincing & durable protection is being catered to the metal surface comprehensively.

Tank External Chemical Corrosion Protection

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The external surface of these tanks are exposed to chemical fumes, moisture and vapours in the location of their installation. Owing to these working conditions the metal surface of the tank has tremendously corroded, although it has been painted with a conventional paint system. Heavy metal loss is seen over the tank surface which was an alarming situation.

Preliminary arrangement to access the complete surface of the tank was made by erecting a tailor-made scaffolding system abiding to safety norms. First round of blast cleaning was carried out to remove the loose rust flakes and old paint from the surface. Surface was scrubbed thoroughly to foaming using cleaning agents and water washed using a high pressure water jet cleaning. This was performed to neutralize the surface and make it free from the entrapped electrolytic chemical molecules.

The neutralized surface was thoroughly blast cleaned using copper slag abrasive medium to Sa 3 surface profile to an average surface roughness of 100+ microns to near white metal finish ensuring the surface is also free from adsorbed contaminants.

Over the prepared surface, ProCoat coating was applied using synthetic rollers and tynex brushes to the recommended thickness levels not exposing the surface for longer times to the expelled chemicals and prevailing humid environmental conditions. Intermittent checks were made using Elcometer WFT gauge to ensure the desired thickness of coating as per the requirements.

Once the coating was cured Dry Film Thickness was measured using the Elcometer DFT Gauge & checked with Holiday Spark Tester to ensure complete coating integrity. Two such tanks have been coated using ProCoat Advanced Polymer Coating Systems providing the reliable protection to these equipments for almost since year 2013.

Over and above ProCoat coating system, as per the requirement of customer, a polyurethane paint of desired colour was applied for the dual protection of chemical corrosion protection and UV degradation, which also gives a subtle aesthetic appearance.

Structures Protection to Chemical & Steam Exposure

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Billet Caster’s supporting structures which are exposed to high temperature steam containing casting chemicals from the hot slab quenching operation has been causing extreme chemical corrosion of structures leading to severe metal loss. Repeated conventional painting methods are unable to yield satisfactory results in terms of protection.


After first round of copper slag blast cleaning to Sa 2 standard, all vertical and horizontal channels are scrubbed with detergent to remove the chemical contamination and further rinsed with fresh water jet to ensure contamination freeness of structures surface.

After surface got dry, carried out with second round of copper slag blasting to achieve Sa 2.5 i.e., near white metal finish with an average surface profile of 85+ microns to attain exceptional mechanical interlocking, polar-polar adhesion and chemical bonding of ProCoat advanced chemical and abrasion resistant polymer coating system.


With thorough hand pressure, initial wetting coat of ProCoat is applied followed by thickness build up coats with tynex bristle brush and synthetic roller over vertical and horizontal beams and allowed for full curing.


Carried out quality checks like wet film thickness during application, dry film thickness after curing, coating integrity check with Elcometer Gauges ensuring flawlessness coating application..

Structural Protection to High Temperature & Chemical Steam Exposure

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Structural I Beams, horizontal channels inside slab caster are under continuous exposure to high temperature i.e., 150°C steam contaminated with casting chemical leading to high degree of corrosion of metal and getting deteriorated in the form of thick rust layers, which is causing reduction of metal thickness. Galvanizing, aluminizing or even high temperature aluminium painting methods have yielded any desired results in terms of protection. ProCoat quality surface cleaning system and application of chemical, temperature and corrosion resistant coating system was adopted based on the coating performance which is safeguarding several plant equipments.

After first round of copper slag blast cleaning to Sa 2 surface finish, all vertical and horizontal channels are scrubbed with detergent to remove the chemical contamination and further rinsed with fresh water jet to ensure contamination freeness of structures surface. After surface was dry, carried out with second round of copper slag blasting to achieve Sa 2.5 i.e., near white metal finish with an average surface profile of 85+ microns to attain exceptional mechanical interlocking, polar-polar adhesion and chemical bonding of ProCoat advanced chemical and abrasion resistant polymer coating system.



Throughout the coating application works, the various quality checks were carried out in order to ensure flawlessness. Deposition of coating was examined using WFT Elcometer Gauge to ensure the thickness levels meet the desired recommendation, upon curing the coating thickness was verified using DFT Elcometer Gauge. Holiday Spark Testing was performed on either side of the casing to identify coating application errors and ensure rigid coating integrity.

Steam Fan Casing Chemical Corrosion Protection

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Hot steam having continuous wet temperature around 100° C mixed with various casting chemicals is making it to be extremely corrosive by forming Hydro Fluoric Acid on Steam Fan casing surface. Suspended particles in the steam flowing at a high speed, also causing abrasion over the surface. Cyclic affect of chemical & abrasion attack on casing surface is leading to punctures in short periods, i.e. within 3 months of operations.


After disengaging the equipment from it’s operation, team ProCoat has carried out the surface preparation & coating application works. Initially the surface was blast cleaned thoroughly and checked for presence of contaminations. On identifying the presence of chemicals, relevant removal methods were carried out ensuring the surface is free from adsorbed contaminants. Blast cleaning was repeated again to attain the surface roughness of an average 100+ microns to Sa 3 Swedish Standards which was measured using the Elcometer Profile Gauge corresponding to near white metal finish which was examined using the shade card.

Over the prepared surface, ProCoat coating was applied using spatulas & synthetic rollers in order to deposit the material all over the surface uniformly. Two different coatings systems were incorporated for this application, an high end ProCoat Coating system was applied on the internal surface which not only provides resistance to corrosion but also the endurance to the accumulation of chemicals by the extreme smooth surface that the coating attains upon curing. The external surface was coated using ProCoat’s chemical resistant coating system to offer the best protection the metal surface from falling prey to the working environmental conditions.


Throughout the coating application works, the various quality checks were carried out in order to ensure flawlessness. Deposition of coating was examined using WFT Elcometer Gauge to ensure the thickness levels meet the desired recommendation, upon curing the coating thickness was verified using DFT Elcometer Gauge. Holiday Spark Testing was performed on either side of the casing to identify coating application errors and ensure rigid coating integrity.

The images on the right hand side corresponds to another steam fan casing that was coated using ProCoat Coating Systems which was examined to check after an operating period of 6 months. The observation has brought forward the intact characteristic of the coating offering required protection to the casing surface from the prevailing corrosive conditions.

Sludge Clarifier Mechanism Corrosion Protection

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This huge clarifier mechanism is intended for the purpose of clarification of sludge coming from scrubbers in a steel industry. The rack arms being continuously immersed in the hot and corrosive liquid which gets drained from the scrubbers has lead to the severe degree of corrosion and abrasion over the structural clarifier mechanism. On draining out the entire clarifier tank the rack arms were found with heavy deposits of sludge simultaneously inducing corrosion all over them.


In order to remove the sludge deposits from the surface, a high pressure water jet cleaning was carried out, followed up with copper slag blast cleaning for preparing the surface prior to the application of coating. Blast cleaning was done ensuring an average surface roughness of 75+ microns, near white metal finish to Ss 2.5 Swedish Standards.

Over the prepared surface, direct application of ProCoat Coating System was carried out using synthetic rollers. The coating deposited over the surface was checked for complete and firm adhesion to the desired thickness which was measured using various Wet Film & Dry Film Gauges followed up with Spark Testing to enhance coating integrity.


Proper planning, quality workmanship & implementation of safe work methods have resulted in performance of the coating applied over this clarifier mechanism to resist the severe degree of abrasive & corrosive immersion conditions since almost three years now.

Scrubber Internal Corrosion Protection

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Specifically, Venturi Scrubber surface has been undergoing extreme chemical corrosion which lead to extreme metal loss in the form of cavities and a through and through hole got developed at one such place on the surface. The corrosive gases being scrubbed with water jets causing chemical sludge deposition over surface that has accelerated a high degree of chemical reaction with metal surface. It was decided for external cladding in many places for strengthening. Internal surface was taken up for metal reclamation and chemical protection with ProCoat engineered polymer coating systems.

The surface inside was blast cleaned twice using copper slag abrasive medium to remove thick corrosion deposits followed up with detergent cleaning & hydro jet water washing. Once the surface was dried up, blast cleaning for the third time was carried out using chilled iron grit to Sa 3 Swedish Standards. Pictures on the left bottom half reveal heavy pitting and cavities over the surface which imply upon the loss of shell metal thickness.

Over the prepared surface, the cavities & pitting were filled with ProCoat Repair & Reclamation Products after which direct application of ProCoat Chemical & Abrasion Resistant Coating System was carried out by roller application. The coating deposited over the surface was checked for complete and firm adhesion to the desired thickness which was measured using Elcometer Wet Film Gauge.

Once the coating was cured, Dry Film Thickness was measured using DFT Elcometer Gauge & Holiday Spark Testing was performed to ensure flawless coating application. Proper planning, quality workmanship & safe work methods followed have resulted in performance of the coating applied over the internal surface of this scrubber vessel to resist the severe degree of abrasive & corrosive operational working conditions prevailing inside.

Pump Casing-Valves Chemical Corrosion Protection

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External surface of these solution circulating pumps and it’s valves are experiencing mild corrosion as these are coming contact with fumes of chemicals emanated from the nearby process vessels and presence of moisture in the atmosphere. On an account of the prevailing corrosion, loss of metal is seen between the mating parts of these pumping components which is leading to leakage of solution being pumped.

Copper slag blasting was initially done to remove the loose rust particles, followed up with detergent cleaning in order to neutralize the surface from adsorbed contaminants. Once the surface was dried up, second round of copper slag blasting was carried out to achieve the desired surface roughness essential for the application of coating.


Coating was applied all over the prepared surface using nylon rollers and brushes to the recommended thickness. Deposition of essential thickness was cross- checked using the Elcometer WFT Gauge.


Once the coating was cured, Dry Film Thickness was measured to make sure the applied coating had been developed to the same as to the Wet Film Coating Thickness.

Pump Base Frames Protection Coatings

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These newly fabricated mild steel pump base frames were to be placed inside the foundations of pumps which would be handling solutions of various concentrations. To safeguard these structural frames from the adverse effect of corrosion, as a preventive measure they were applied with ProCoat Coatings to offer resistance to corrosion beneath the submerged concrete bed.
Prior to application of coating, the frames were blast cleaned using copper slag medium to attain the desired surface roughness that corresponds to Sa 2.5 Swedish Standards with an average surface roughness of 75+ microns.

Over the prepared surface application of coating was carried out using nylon rollers and tynex bristle brushes. Initially a high hand pressure wetting coat was given followed by low hand pressure thickness deposition coats to the recommended thickness levels. At the corners, intricate portions coating work was carried out with brush application. The thickness of coating being deposited over the surface was measures using the WFT Elcometer gauge during the application works. On curing the dry film thickness was measured using DFT Elcometer Gauge & Holiday Spark Testing performed to ensure flawlessness.


The pumps have been commissioned in the year 2012 immediately after the completion of coating works. And since then there has been no sign of corrosion observed over any of the visible skeletal structure of these base frames.