High Performance Coating Solutions for Metal Protection

High Performance Coating Solutions
Metal Reclamation &

We are a service-oriented organization who believe in providing optimized protection to a metal substrate
by careful & thorough examination. Inspecting & analyzing the root cause of the corrosion phenomena,
recommendation of the desired protection mechanism to serve the specific purpose, narrowing down the
product selection to end user, keeping in view the intended purpose to be resolved for validated extended
durations.
In order to establish necessary genuine protection with the application of coating system, one needs to
opt for exemplary surface preparation of the substrate which is very important, most crucial & is a must.
We at ProCoat strongly believe in quality work execution, and uncompromisingly follow stringent surface
cleaning methodology. Irrespective of the dimensions, shapes and lengths, the surface is blast cleaned to
attain the desired surface roughness, by proper work plan, adhering to safety standards, meeting and
attaining the surface profile resembling to Swedish Standards. We are equipped with the necessary
infrastructure for the work execution. Though this method of blast cleaning is tedious & cumbersome
procedure, yet we adopt the system in all the applications to fetch the extraordinary outcomes.
Value addition of ProCoat in the field of Corrosion Engineering extending it’s hand in,
 Supporting & understanding the corrosion aspects and retaliating causable reasons.
 Educating officials about the present practices and desired improvements in the field of
corrosion protection.
 Preparing inspection reports for better understanding prospectus.
 Enlightening the advantages of ProCoat advanced polymer coatings; demonstrated and
proven in critical areas in comparison to conventional practices.
 Introducing an international standard “corrosion protection methodology” in achieving
absolute metal protection.
 Providing Turn-Key solutions for Corrosion Protection Requirements, equipped with
dedicated air compressors & blasting set up for blast cleaning, implementing relevant tools
for coating application & instruments for quality analysis of applied coatings, having a crew
of experienced team of applicators..
 Conducting periodic inspections to the sites where work execution is already completed to
analyse and keep a check over the protection system.
 Attending any warranty related work as per the commitments with a clear vision to enhance
the life of equipments, structures and towers under our protection system.
 Last but not the least, always keeping Safety in mind & following it religiously at all times
during the work execution.
Profile
ProCoat Specialities Pvt. Ltd.

ISO 9223 :
Classification
Atmospheric
Corrosivity
Corrosivity Typical Out Door Conditions Corrosion Of
Mild Steel
Corrosion Of
Galvanized Iron
C1 Very Low Dry, Very Low Pollution Around 1.3 microns/
year
0.2-3 microns / year
C2 Low Varying Temperatures, Low
Humidity, Low pollution
1.3 to 25 microns/year 2-16 microns / year
C3 Medium Moderate condensation,
Moderate pollution
25-50 microns / year 16-25 microns /
year
C4 High High condensation, high
pollution
year
C5 - I
Very High Industrial Temperate & sub tropical with
very high sulphur emissions,
humidity
year
C5 - M Aggressive Marine Saline, Tidal, high humidity 80-200 microns / year 20-30 microns /
year
CX Extreme - Industrial
cum Marine
Very high saline, very high
industrial pollution, Chemical
pollution
200-700 microns + /
year
30-80 microns /
year
Atmospheric Corrossivity &
Deteriorations Of Mild Steel & Galvanized Iron
CORROSION OF STEEL
Above explained categories of atmosphere, influence accelerated degree of corrosion of metal. Apart from these categories,
many more types of exposure conditions such as, high temperature steam, heated water, heated salt water, acids, alkalis
and mixed mediums along with temperature prevail in operational conditions where metal / concrete substrates gets
exposed typically over process vessels, equipments, structures / tanks etc which leads high to severe degree of metal
corrosion and turn into complete metal loss if not protected in desired methods. ProCoat Specialities is in to “chemical &
corrosion protection of metal” and succeeded in many harsh exposure conditions with advanced coating systems along with
high end quality work execution systems.

Corrosion - Mild Steel
In all forms of corrosion of metal, fundamental influencing parameter is
The Physical & Electrical Contact of Electrolyte (environment / medium) with Metal
Rate of corrosion of mild steel depends upon the “conductivity of electrolyte” i.e., mild steel corrosion increases
when comes in contact with Moist Air—Moisture—Water—Seawater—Steam—Chemical
Fumes—Alkalis—Acids—Mixed Medium and if these mediums has tempera-
ture, corrosion gets accelerated. Along with corrosion reaction, if the medium has abrasive particles,
abrasive erosion of metal also takes place which is a faster deterioration pattern of metal substrate.
 Ore which is in STABLE state when converted in to metal,
becomes ACTIVE.
 In a piece of metal Anodic & Cathodic areas forms
automatically due to potential difference, Impurities &
surface irregularities cause electron & Ionic conduction
starts and circuit gets completed when it comes in contact
with moisture and oxygen, nothing but electrolyte.
 Corrosion is an electrochemical reaction of metal with
electrolyte ( i.e., with which metal is coming in contact).
 In the corrosion reaction, metal starts forming oxide layers
in the form of flakes, and localized deterioration i.e., pitting,
increment of pitting into cavities, which ultimately lead to
loss of metal thickness and mechanical strength
 Negligence leads to replacement of structure or equipment
Uniform / General Corrosion
With uniform distribution of cathodic
reactants over the entire exposed metal
surface, reactions 2H+
+ 2e = H2 and/or
O2 + 2H2O + 4e = 4OH-
take place in a
"uniform" manner and there is no
preferential site or location for cathodic or
anodic reaction. The cathodes and anodes
are located randomly and alternating with
time. The end result is a more or less
uniform loss of dimension.
Crevice Corrosion
Crevice corrosion is initiated by a
difference in concentration of some chemical
constituents, usually oxygen, which set up
an electrochemical concentration cell
(differential aeration cell in the case of
oxygen). Outside of the crevice (the
cathode), the oxygen content and the pH are
higher - but chlorides are lower. Crevice
corrosion depends on metal-to-metal, metal-
to-non-metal, gap size, depth, surface
roughness, composition, pH, temperature,
halide ions, oxygen.
Bi-Metallic Corrosion
The potential difference (i.e., the voltage)
between two dissimilar metals is the driving
force for the destructive attack on the active
metal (anode). Current flows through the
electrolyte to the more noble metal (cathode)
and the less noble (anode) metal will corrode.
The conductivity of electrolyte will also affect
the degree of attack. The cathode to anode
area ratio is directly proportional to the
acceleration factor.
Pitting / Localized Corrosion
Pitting Corrosion is the localized corrosion of
a metal surface confined to a point or small
area, that takes the form of cavities. Pitting
Corrosion is caused by the ENVIRONMENT
(chemistry) that may contain aggressive
chemical species such as chloride. Chloride
is particularly damaging to the passive film
(oxide) so pitting can initiate at oxide breaks
and aggravates into cavities / holes
Microbiologically Induced
Corrosion : MIC is caused by specific
genera of bacteria which feed on nutrients
and other elements found in waters and
soils. Sea water is a primary source of
sulphate reducing bacteria (SRB). The
biological activities modify the local
chemistry (acid-producing) and render it
more corrosive to the metals. For
example, iron-oxidizing bacteria can
perforate a 5mm thick 316 stainless steel
tank in just over a month!
Erosion Corrosion
The mechanical effect of flow or velocity of a
fluid combined with the corrosive action of
the fluid causes accelerated loss of metal.
The initial stage involves the mechanical
removal of a metal's protective film and then
corrosion of bare metal by a flowing
corrosive occurs. The process is cyclic until
perforation of the component occurs.
Frequently Observed “Types Of Corrosion” In Industries

Corrosion - Galvanized Iron (GI)
Hot Dip Galvanizing is a process of dipping mild steel member into a molten zinc metal by
following stipulated duration of dip and angle of dip to get a metallurgical reaction of mild steel
and zinc. Typically a 125-185 microns of zinc thickness is being done in galvanizing process.
Galvanizing is expected to protect mild steel for >30 years in a normal atmospheric conditions.
Where as if galvanized iron is exposed to aggressive corrosive / salty atmosphere, zinc tend to
deteriorate and lead to corrosion of mild steel. The deterioration phenomena of Zinc is explained
as follows:
 Mild steel (Ferrous Metal) + Zinc coating = Galvanized Iron : Reactions taken place are..
 Zinc + Oxygen = Zinc Oxide ( a powdery substance)
 Zinc Oxide + Moisture = Zinc Hydroxide ( White rusting of Zinc)
 Zinc Hydroxide + Carbon Dioxide = Zinc Hydroxicarbonate (Also called a stable layer i.e.,
ZINC PATINA and it takes around 6 months time to form this from the moment of dipping in
molten zinc and subjected to free air flow contact with galvanized angles)
 The above are layers formed in the given galvanized thickness over mild steel.
 This so called “Zinc Patina” will never further react with oxygen, carbon dioxide and moisture.
But when this layer is exposed to industrial pollutants like chlorides, sulphates and moisture,
then it starts reaction (deterioration) as follows:
 Zinc Hydroxicarbonate + Sodium Chloride = Zinc Chloride + Sodium Hydroxide ( powdery
substance, loose and soluble in water)
 Zinc Hydroxicarbonate + Sulphur dioxide = Zinc Sulphate (Powdery substance and soluble in
water)
 Zinc Hydroxicarbonate + Oxides of Nitrogen = Zinc Nitrate ( Soluble in water)
 Eventually all zinc from patina (galvanized iron) consumed by these reactions and beneath
mild steel is exposed to corrosive environment)
 Since mild steel is active, automatic formation of anodes and cathodes takes place due to
metallurgy, surface undulations, impurities in iron. This active surface undergoes,
 Cathodic reaction : 2Femetal= 2 Fe2+
+ 4e-
 Anodic Reaction : 2H2O + O2 + 4e-
= 4OH-
 Further Reaction : Fe++
oxidise to give Fe+++
(ferric ions) ; Fe+++
reacts with hydroxide to form
= Fe2O3 (rust)
 Ferrous will react with Sodium chloride and sulphur dioxide to form ferric chloride and ferrous
sulphate which are nothing but layers of metal result in loss of metal thickness.
 Other reactions of ferrous with oxides of nitrogen produce ferric nitrate which is a crystalline
salts which tend to detach from the surface resulting reduction of mild steel thickness.
 When Galvanized Iron members are exposed to CX-M environment i.e., saline + industrial +
chemical environment, deterioration of zinc takes place in extremely accelerated speed.
At these environments, DUPLEX coating systems i.e., Galvanized Iron + High End Epoxy System
is the only solution to maintain the strength of GI structures. ProCoat advanced, solvent free
Novolac polymer coatings are proved in GI Protection at CX-M, C5-M atmospheric categories.

Corrosion - Concrete
A properly designed and constructed concrete is initially water-tight and the
reinforcement steel within it is well protected by a physical barrier of concrete cover
which has low permeability and high density. Concrete also gives steel within it a
chemical protection. Steel will not corrode as long as concrete around it is impervious
and does not allow moisture or chlorides to penetrate within the cover area. Steel
corrosion will also not occur as long as concrete surrounding it is alkaline in nature
having a high pH value.
However, Reinforcement Cement Concrete (RCC) structures are also mortals,
.ageing of concrete will lead towards various problem like spalling, craking,
reinforcement corrosion, chemical attack, loss of mechanical strength etc. Depending
on the quality of design and construction, there will be an initial period in which no
corrosion will occur as the external moisture or chloride is unable to reach the steel
causing corrosion. This initial period will also depend on the environment in which the
structure is constructed. Due to wetting and drying cycles, heating and cooling
cycles, loading and unloading cycles, cyclic loading, leaching of lime and most
importantly additions and alterations done on the structures, isolated cracks, voids,
entrapped air and large capillary pores get interconnected and external moisture and
chlorides find their way to reinforcement steel and corrosion starts. Corrosion process
continues till such time large, cracks develop and spalling of concrete occurs.
Besides moisture and chloride ingress problems, carbonation is also one of the
principle causes of corrosion. Concrete when produced is highly alkaline having a pH
value between 12.5 to 13.5. Alkaline environment around the steel passivates
corrosion process. Due to carbon dioxide and humidity present in the environment the
exposed surface of concrete loses its alkalinity due to formation of carbonic acid. This
formation gradually penetrates into the concrete mass and is called carbonation of
concrete. When carbonation takes place beyond the concrete cover given to
reinforcement steel, the environment around the steel loses its alkalinity (dropped to
less than pH value 9). The mitigation of corrosion no longer takes place due to
chemical protection. It is observed that lower grades of concrete have shown much
deeper carbonation, than higher grades of concrete, for a similar period of time. In
acid or excessive alkaline exposure conditions, the deterioration pattern will be much
faster which lead to formation of rust layers over rebar’s which increase volume inside
and exerts external thrust towards concrete cover, leading to formation of cracks.
More the cracks formation more the ingress of chemicals and hence more
deterioration takes place. Due to this detachment of concrete cover from rebar’s
position i.e., spalling is inevitable and demands repair & re-strengthening
requirements. In such environments where concrete is expected to get exposed such
as, continuous immersion conditions of chlorinated water, spillage of acids and
alkalis, frequent dry and wet conditions, it is always advisable to have protection of
concrete with high performance, chemical resistant, barrier polymer coating systems
to address these problems.

Microbiologically Induced Corrosion ( MIC )
MIC of metal is a corrosion process of micro-organism e.g.,
bacteria. There are many types of bacteria available
including slime forming (Pseudomonas Aeruginosa), acid-
producing, sulphate-reducing (Desulphovibrio), iron-
oxidizing and iron-reducing. Initially a bio-film is formed over
surface and undergo multistage process of organic
conditioning of surface by absorbing organic molecules,
transportation of Planktonic organisms to the solid surface,
formation of occluded surface cells, formation of patchy
surface colonies by micro-organisms, attraction of extra
cellular polysaccharides to aggregate biological and non
biological species to grow from thin layers to centimetres
with a population density of 100 to 1000000 bacteria per
square centimetre of surface. A typical 10000 bacteria
count in a square centimetre is enough to change
environment beneath colony to develop a galvanic cell. As
the microbes grow, they form a gelatinous mass that isolate
microbe colony from fluid flow pressures and also this bio
film formed over bacterial colony protects it from biocides.
These layers form crevices in which regular crevice
corrosion is initiated. Within these bio-films, numerous
organisms such as acid producing bacteria, sulphur
reducing bacteria, sulphur forming bacteria, iron reducing
bacteria etc can change pH value for more than three units
locally i.e., localized intensity of chemical attack at the
interface of bio-film and metal.. Anaerobic bacterial gets
protected by aerobic bacteria. Iron is the essential nutrient
for Pseudomonas Aeruginosa which gets access to metal
first and transport solubilised ferric ions by chelation
process. Due to localized chemical attack having pH 3-6, pit
formation is initiated by sulphide stimulation of SRB in the
electro-chemical process of corrosion as the formed
sulphides are cathodic to the steel and attack the surface by
consuming anodic iron i.e., pit area. The bacteria reduce
inorganic sulphate to sulphide which remains as dissolved
sulphide and liberated as hydrogen sulphide gas and also
reacts with ferrous ions to produce the characteristic black
precipitate of iron sulphide. The overall chemical reaction
can be described as :: Fe + 2H+
Fe2+
+ H &
4 Fe + SO4
2-
+ 4 H2O = FeS + 3 Fe(OH)2 + OH-.
Since microbes survive for longer periods, formed pits grow
in to deeper and capable to puncture steel. SRB also have
an important role in freshwater owing to an active sulphur
cycle. It is therefore important that sulphate reduction can
occur at freshwater sulphate concentrations because
Desulfovibrio species have a high affinity for sulphate.

Corrosion Under Insulation ( CUI )
Corrosion Under Insulation is a major problem. When insulation becomes wet it creates the potential for corrosive failure of
the equipment. In chemical environment, where process fumes, steam or liquid leaks from flanges (as shown in photos) are
quite possible to enter through the joints and minute gaps over metal Jackets of insulated vessels.
VOIDS, JOINTS, OPENINGS,
DAMAGES on EXTERNAL JACKETS
from where these chemical substances
enters and WOOL gets SOAKED with
them. Insulation wool absorbs these
chemical and moisture molecules
and becomes wet conductive
electrolyte source permanently on
METAL.
When metal comes in
contact with this
ELECTROLYTE, it
undergoes
continuous reactions
and entire metal
surface CORRODE in
various forms like
PITTING
Corrosion in the forms of Uniform,
localized on surface and CREVICE
corrosion at oxygen restricted
areas like pipe flanges, joints etc
takes place under insulation.
Schematic of above explained CUI
Wool i.e., rock wool or glass wool, being used for insulation, absorbs these chemicals and moisture, and retains permanently.
Chemicals and moisture soaked wool will be always in contact with metal substrate of equipment (pipelines, ducts, tanks,
process vessels etc) and form an excellent conductive electrolyte source on metal.
ProCoat Barrier Cum Chemical Resistant Coating Before Insulation To Prevent CUI

Method of Glass Flake Lining
Above referred methods are “MULTILAYER LINING SYSTEMS” and ensuring quality in practical working conditions
is extremely difficult and hence PREMATURE failures takes place and cause damage to substrate.
Glass Flake Systems : Acrylic Vinyl esters reinforced with glass flake particles is the system coat applied over a
solvent based primer surface and top coated with a veil coat containing styrene
Rubber Lining: A solvent based primer on surface, a rubber adhesive application on primer, fixing of soft layer of
rubber sheet first and hard rubber layer later, vulcanizing of rubber sheets and heat curing
FRP Lining: A solvent based primer on surface, spreading of fibre glass mat and application of a resin as top coat
over fibre mat and a top veil coat.
Observed failure mechanisms of all the above three methods ( Glass Flake, Rubber lining & FRP lining) are mostly
due to the following:
 Adhesion Failure with substrate & Inter-coat adhesion failure ( de-lamination )
 Cohesive Stress Failure. Osmotic Blistering, Ageing, Thermal Cracking, UV degradation
 Ingress of corrosive substances through the porous texture of applied layers.
 Extreme field difficulty in implementing cumbersome application procedure of number of layers, inter-coat schedules etc.
 Impossible accuracy in mixing of material by means of Weighing modes of resin and hardeners.
 Solvent based system leads to formation of micro porosity over primers and adhesives leads to permeability of handling
medium and hence underneath corrosion and lead to failure of lining.
 Poor engineered strengths such as compressive, impact and chemical and temperature resistances when used for
internal protection of equipment.
Glass Flake, Rubber & FRP Linings
Performance Evaluation In Highly Corrosive Exposures
ProCoat Systems are formulated with 3 to 3.6 functionality, 100% solids, solvent
free, high performance Novolac Epoxy Systems with ceramic, carbide, zirconium
and Kevlar fibres designed to offer “barrier protection to metal”, “chemical
resistance”, “high wet temperature resistance” and high end mechanical strength so
that applied coating system sustains on surface and effectively address the harsh
operating conditions either inside vessels or external areas of industrial equipment.
Being single coat system without any primers, optimum mechanical interlocking,
polar-polar adhesion and chemical bonding with thoroughly grit blasted steel takes
place and offers assured protection to substrate.
Failure Of Glass Flake Lining
Failure Of Rubber LiningMethod of Rubber Lining
Bulging & Failure Of FRP LiningMethod of FRP Lining
ProCoat Lining System

Practical Observed Failure Modes Of Solvent Based
Conventional Paints In Corrosive Industrial Zones
Conventional Paints ( i.e., Primers, Intermediates & top coats any of these) basically consisting of
 Resins / Binders ( Synthetic, Polyester, Vinyl ester, Coal tar, Alkyd, epoxy, polyurethane based binders )
 Pigments ( powders give opacity and colour for paints)
 Solvent( >= 50% solvents in the given unit of paint liquid)
 Extender ( Large pigment particles added to improve adhesion, strengthen the film and save binder)
 Additives ( Used to modify the properties of liquid paint or dry film)
All these constituents put together called a PAINT, which is falls under economical range for industries.
SOLVENT EVAPORATION (for the purpose of drying of paint film) : High content of solvents starts evaporating from
the freshly applied paint film which reduces (shrinkage) the thickness of film by more than 50% and still gets entrapped in all
the layers of three coat systems and lead to form micro pores over painted surface along with internal stresses.
Primer Coat
Magnification - 50 x
Undercoat
Top Coat
This drying process leads to
Formation of MICRO-POROUS
surface over PAINT LAYER with
possible interconnections through
all the layers forms BREATHING
PATH to METAL SURFACE
COHESIVE STRESS : Due to poor SOLVENCY and SLOW rates of
commercial grade solvent, evaporation will never be complete and fast,
which results to develop cohesive stress in between paint layers and
under temperature exposure. More thickness of paint leads to inherent
stress and underlying layers lose their elasticity in respect to outer
layer hence get lifted and starts blistering, cracking.
POOR & LOSS OF ADHESION : Due to poor film properties,
conventional paints can not get proper adhesion either with the
substrate or in between paint layers and tend to peel off from
surface due to underneath corrosion (caused due to ingress of
chemicals through pores) and impractical adherence to overcoat
schedules and contamination deposition between layers
UNDERNEATH CORROSION : MICRO POROUS
surface developed due to solvent evaporation makes
METAL to BREATH moisture, oxygen and corrosive
molecules through these PORES and undergoes
CORROSION. Since ingress is throughout the painted
surface, entire metal surface undergo corrosion and forms
a LAYER OF RUST BENEATH PAINT. Within very short
periods, metal corrodes in-spite having paint over it.
POOR Mechanical, Chemical And Temperature Resistances : As these commercial grade conventional paints are
formulated with general resin systems, their poor chemistry cannot give necessary physical and mechanical strengths like
abrasion, scratch resistance, impact, temperature resistance and cannot take the effect of Salts, Acidic, Alkaline exposure
conditions, generally prevailing in industrial zones. Therefore, if the equipment or structure is intended to have a barrier
protection by retaining the structural dimensional stability, usage of conventional epoxy, synthetic, coal tar, polyurethane
based paints is not at all recommended based only commercial viability in the exposure conditions like high humidity,
chemical gaseous exposure, saline exposure.

Differentrustgrades-Manual-Blast
cleaningstandardsOfCorrodedSteel
ProCoat Service Team in any
application ensures either Sa 2.5 /
Sa 3 i.e., Near white metal
finish / White metal finish while
executing coating works.
Corrosion Grades & Cleaning Standards
Differentrustgrades-Manual-Blast
cleaningstandardsOfPittedSteel

Metalizing - Performance In Chemical Ambience
By expecting CATHODIC protection to Mild Steel, industries adopt Metalizing method either
with ZINC or ALUMINUM hot spray on cleaned steel. It is observed that these methods are
offering protection to Mild Steel in moderate corrosive environment of coastal where less
condensation of moisture and salts as well as in mild industrial environment. The deposited
zinc or aluminium gets sacrificed slowly by undergoing reactions with environment and
offers protection to mild steel. In-situ galvanizing or metalizing method is comparatively has
very lesser life in comparison to Hot Dip Galvanizing at these environments.
Corrosion of Metalized Structures - Due To Chemical Exposure
Deterioration pattern of Zinc: When Zinc coated surface area exposed to SOx, NOx, Chlorides etc ( and direct
chemicals like HCl, H2SO4, NaCl, Nitric Acids etc or Fumes of these chemicals), reaction substances like Zinc Chloride, Zinc
Sulphate, Zinc Nitrates are formed over metalized surface in the form of “powdery substances” which has the tendency to
dissolve in water and are loosely attached to the surface and can be removed by heavy wind flow. These reaction products
are nothing but “consumption of zinc” from the Galvanized Iron and these reactions continue till entire zinc gets converted into
salts and then exposes beneath mild steel. Zinc is also a metal like mild steel and is subjected to under reactions with
chemicals either Acids or Alkalis. Deterioration of Aluminium: Similar to Zinc, Aluminium is also a metal and undergo
chemical reactions when exposed to highly corrosive chemicals. Aluminium chloride, aluminium sulphates etc are the
resultant substances of chemical reactions under moisture and gradual deterioration of takes place.
ProCoat, Solvent Free, Novolac Polymer Chemical Resistant Coating System
Where as in such harsh exposure conditions such as, high wet temperature, chemical fumes, steam, salts precipitation on
mild steel, ProCoat coatings are outperforming in the place of metalizing. Because, ProCoat coatings are formulated with
high end Novolac chemistry which is meant for chemical resistance as well as high temperature resistance. Over thoroughly
blast cleaned surface, applied ProCoat coatings are forming a highly impermeable, barrier type lining which resist the
chemical attack, penetration of highly vibrant steam molecules and isolates the metal from the physical and electrical contact
of medium hence metal gets protected for extended periods.

Failure Of Synthetic, Zinc Rich, Epoxy Paint Systems
In Highly Corrosive Environments
For the protection of MS / GI structures located in Industrial & Chemically Polluted, Saline Zones electricity substation /
transmission towers, clients used and tried many kinds of paint systems, but none of them yielded for more than 2 years and
ended up with failure of paint as well as deterioration of metal thickness. These practices also lead them to replace structures
on account of corrosion before designated life.
Red Oxide + Two Coats of Aluminium Paint : This system shown deterioration within 3 months of application and
aggravated underneath corrosion is taken place leading to complete deterioration of paint as well as layers of rust was formed
over metal within 2 years of painting.
Primer + Epoxy Paint + Polyurethane Top Coat System : This system shown deterioration within a span of 18
months as shown above and deteriorated completely along with severe metal loss of painted structure and eventually
replaced with new ones. This happened due to severe chemical reactions with MS in-spite of having paint over it.
Zinc Rich Primer + Chlorinated Rubber Paint System : This paint system applied over GI structure located in Acid
Rain Environment and the paint system failed less than 2 years and exposed GI to chemically polluted environment, which
lead to consumption of total zinc and aggressive metal loss of MS and reached above condition within 8 years of installation.
Zinc Chromate Primer + Anti-Corrosive Epoxy Paint System : This paint system applied over GI structure located in
saline cum industrially polluted zone, which shown the absorption of chemical molecules and moisture through it from the
developed micro porous surface due to solvent evaporation and failed to protect.
Epoxy Primer + Polyurethane Top Coat : This system performance can be seen in the above pictures, paint
de-laminated and surface beneath paint is started corrosion after zinc runoff from galvanized iron in a span of just 3 years.

CAVITATION, ABRASION & CORROSION OF PUMPS
Vertical Turbine Pumps, Centrifugal or Split Casing pumps handling sea water,
river or raw water are subjected to abrasion and corrosion due to continuous
immersion and operational conditions. Specifically internal surface undergoes
“cavitation erosion”, “abrasive erosion” and “corrosion” problems..
Cavitation Erosion: Is caused due to formation of micro bubbles under
pressure differences and travels to the walls of pump’s rough surface and implode,
collapsing is asymmetrical with micro jet with high kinetic energy which produce
hammering effect over the grain boundaries of metal and forms a dent. Continuous
and innumerable implosions makes dent to form a cavity. More the cavities over
surface more turbulence of water medium and hence more generation of bubbles
and implosions over metal body.
Abrasive Erosion : Is the mechanical removal of metal by suspended solids in
the fluid. The rough surface of the pump greatly aids in increasing contact time of
fluid and friction with the surface. The increased friction due to flow result in surface
wear.
Corrosion: Corrosion damage to the submerged metal surface is the result of
electrochemical reaction. Water with dissolved oxygen being an electrolyte and
galvanic current passes from anodes (impurities of metal and rough surface) to
cathode (whole metal surface) completing the circuit for inducing galvanic corrosion.
Continuous formation of anodic surfaces due to abrasive action over metal surface
induce more corrosion process and dissolving of anodic areas due to removal of
passive oxide layers during pump operation. During the corrosion phenomena
swapping of polarities takes place and eventually entire metal gets rusted. The
interlinked actions of Cavitation Eroison, Corrosion and Abrasive Erosion in
most of the pumps lead to loss of metal in the form of cavities, causing more
turbulence, increase power consumption and reduction in operational life.
ProCoat Solution: These abrasion-erosion, cavitation & corrosion
problems of pump casings as well as impellers can be addressed by
adopting a high performance polymer coating system which has the
following performance characteristics such as,
 Smooth, low friction surface to reduce the contact time of liquid so that
friction can be reduced, outflow is improved and results in reduced
power consumption and increase in efficiency.
 Desired flexibility in coating with modified flexiblizers which reduces the
plastic deformation effect of bubbles and hence cavitation can be
addressed
 Toughness and mechanical strength of coating by means of having
ceramic, carbide and zirconium fillers to address erosion/abrasion
action of fluid & its suspended solids.
 Advanced chemistry which makes coating to form a
barrier lining over pump / imperller surface to
prevent the ingress of water molecules so that metal
gets isolated and hence corrosion is addressed.

Conventional Paint Deterioration Pattern
It is observed that, irrespective of “atmospheric exposure conditions prevailing at substations / transmission towers”
conventional red oxide + two coats of aluminium painting method is being practiced by electricity boards once in 5-years
In industrially polluted, moist and saline zones, present practice of aluminium painting is not at all yielding any kind of
protection to Mild Steel substation structures / transmission towers. Technically, applied paint shown deteriorations in the
form of PITS / RUST SPOTS within 3 months of time. From then, formation & its size of pits getting increased.
Simultaneously, metal under this paint undergoing localized corrosion with atmosphere and forming a LAYER OF FERROUS
OXIDE i.e. RUST LAYER. The rate of corrosion formation is directly depends upon the severity of atmosphere and
accelerates to high degree of RUST beneath paint. Firstly, these conventional paints consists around 70% of solvents in it.
They tend to evaporate slowly and continue during life time of paint due to its poor solvency property under the influence of
ambient temperature, they form MICRO PORES on painted surface. All three layers of paint i.e., red oxide & two aluminium
coats contains solvents, hence from all layers the evaporation and formation of micro pores takes place from ALL OVER
PAINTED SURFACE. Virtually metal gets access through these micro pores with atmosphere. This makes METAL TO
BREATH oxygen, moisture, chemical molecules and gets CORRODE. Secondly, poor adhesion (bonding) of red oxide with
metal & 1st coat of aluminium with red oxide, second coat of aluminium with 1st coat of aluminium (inter layer adhesion)
results in developing COHESIVE STRESS and lead to LIFTING OF LAYERS during this solvent evaporation process. At the
same time, due to solvent evaporation, applied layers gets SHRINKED to almost 70% aids in more stress in drying paint.
Thirdly, being general purpose synthetic resin chemistry, the chemical effect of saline salts, sulphur dioxide, oxides of
nitrogen and other constituents of atmosphere will starts eroding the aluminium paint in no time. Apart from this, no
mechanical strength, toughness found in this paint system to withstand the harsh atmospheric conditions. In-spite of
repetition of aluminium painting even ONCE IN SIX MONTHS, will never yield PROTECTION to MILD STEEL at these harsh
atmospheric conditions as the same phenomena of deterioration will repeat and eventually METAL LOSS WILL TAKE
PLACE ON STRUCTURE and leads to unavoidable REPLACEMENT option. Finally, the surface cleaning method practiced
is not facilitate any kind of bonding of paints with the substrate as residual corrosion, contamination, paint traces will prevent
the adhesion of fresh applied red oxide & aluminium paint. It is also observed adding additional thinner is aiding in formation
of pitting in much accelerated way. Inversely, by keeping the “corrosiveness of atmosphere in view”, if the surface is cleaned
optimum, then deterioration of these paints will tend to be much faster due to above explained “micro-porous formation &
reaction with metal phenomena”.
Here one coat of REDOXIDE & two coats of ALUMINIUM paint applied. In just 3 months
after painting, pitting / rust spots are started appearing and keep on increasing the intensity
when time is lapsing. It is to note here that, PAINT IS GETTING DETERIORATING & AT
THE SAME TIME METAL BENEATH PAINT IS ALSO DETERIORATING.
Metal PROTECTION is not ACHIEVED HERE. Moreover money / time spent on
conventional painting is not giving any benefit.
BARRIER PROTECTION : Where as at this portion of structure, PROCOAT coating is
applied and around 8+ years is already crossed and NO SINGLE RUST SPOT / PITTING IS
OCCURRED. This indicates, PROCOAT coating is NOT ALLOWING THE CHEMICAL &
MOISTURE MOLECULES PENETRATION THROUGH IT and ABSOLUTELY ISOLATING
THE PHYSICAL AND ELECTRICAL CONTACT OF CORROSIVE MOLECULES WITH THE
METAL. Beneath PROCOAT coating, METAL IS ABSOLUTELY PROTECTED. Therefore,
NO DETERIORATION OF METAL is taking place hence DIMENSIONAL STABILITY OF
STRUCTURE IS ACHIEVED. With this PROCOAT protection, REPLACEMENT OPTION
OF MS / GI Structure / Tower will NEVER ARISE in FUTURE if maintained.

ProCoat Quality Work Execution System
Corroded Surfaces Scaffolding First Round Blast Cleaning
Coating Integrity CheckColour Coding Top Coat Fully Applied ProCoat Coating
ApplicatorSafetyEquipment,
TestingInstruments,Surface
CheckingConsumables,Surface
PreparationEquipment

ProCoat service personnel are
 Trained for procedures of WAH,CSE,LOTO,PTW,ESS,MG,PPE, RS,CS etc.
 Posses health fitness certificates
 Trained & Experienced in protective coating applications
 Most importantly having quality service mind set.
Offering dedicated services to enhance the life of critical and costly equipment.
Steps & Scope of work execution by ProCoat
1. Safety Equipment usage & Safety Implementation during work as per norms
2. Mobilisation of Air compressor, Blast generators, blasting medium, application
tools, quality checking instruments
3. Surface contamination checking test kits usage during work
4. Tailor made scaffolding arrangement as per safety norms
5. Evaluation of corrosion problems and framing desired work execution system
6. 1st Round of copper slag blasting to remove existing paint, rust from surface
7. Surface contamination checking with relevant test methods
8. Removal of identified surface contamination by adopting appropriate methods
9. 2nd round copper slag blasting to reveal “white metal finish” as per Swedish
Sa3 standard
10. Surface roughness / profile checks with Elcometer gauges to ensure polar-
polar bonding, chemical adhesion and mechanical interlocking of coating with
substrate
11. Application of selected ProCoat coating over thoroughly prepared surface with
tynex bristle brushes / synthetic roller / airless spray methods
12. Checking of coating thickness with Elcometer gauges and recording
13. Checking of coating integrity with Elcometer porosity detector and ensuring
flawlessness of coating over surface
14. Application of colour coding system over and above ProCoat system to meet
requirements of end user and need on case to case.
15. House keeping and disposal of debris in designated areas
16. Submission of detailed work execution report to customers for future records
Surface Contamination Checks Second Round Blast CleaningContamination Removal
Surface Roughness Check
ProCoat Coating Application
White Metal Blasted Surface
Coating dry film thickness check Coating wet film thickness check
ProCoat Quality Work Execution System

1st Important Point for Performance :
High End Chemistry & Characteristics of ProCoat coating
ProCoat Coating Performance Characteristics
White Metal Surface
Finish (Sa 2.5 / 3),
Thoroughly cleaned
metal to make
“Contamination Free”
& Surface Profiled
( Surface Roughness) Curing by polymerisation reaction to
form a High density, highly complex,
3-3.6 dimensional cross linking
polymer matrix lining with excellent
resistance to permeability, which
meets “Physical Isolation of Metal
from corrosive chemical & moisture
molecules
Coating attains “Polar-
Polar Bonding”, “Chemical
Bonding” & “Mechanical
Interlocking” with substrate
and sustain on surface to
protect
Exposure conditions: Coating is possible to get exposed to
SALINE salts, STEAM, SEA WATER, Immersion, Industrial
pollutants such as NOx, Cox, SOx, Acidic, Alkaline or Mixed
chemical effects and even under variable temperatures,
cyclic temperature variations and even flow or Immersion
conditions based on equipment location in various
industries.
2nd Important Point for Performance :
Strict adherence of Surface cleaning, coating application, quality checks throughout the work execution ensures
optimum adhesion, curing of coating and protection to metal. ProCoat Specialities Application Team strives for
achieving this quality method, resulted in establishing acceptable protection performance to JSW costly and
critical equipment from past many years.
Single coat system
directly applied on
prepared surface
without any primers
Attains high Tg (Glass Transition) temperatures of 115 / 170
o
C without any changes in coating chemistry
ProCoat coating effectively
passed 5000 hours of
“SALT FOG” & “HUMIDITY
CABINET” exposure which
makes the coating resistant
to “undercut corrosion” &
“immersion protection”
ProCoat Coating sustain without spreading the
flame and limiting the damage to localized even
in the event of high temperature exposure
Absolute Metal Protection is possible only when the applied coating has excellent chemistry and adheres properly
with substrate and resist the ingress of chemical molecules and isolates metal surface from the physical and
electrical contact of medium along with excellent engineered mechanical strengths, temperature and chemical
resistance. ProCoat Coating are capable for this kind of protection.
ProCoat coating posses exceptional mechanical strengths
such as “Tensile strength,” “Shear strength”, “Compressive
strength”, “Flexural strength” & Peel off strength” which
makes the coating tough, durable and dependable

Corrosion Problems - Various Process Equipment
PIPELINE EXTERNAL CORROSION
Pipelines are being an important equipment in any industry for
handling liquids / gases and expected to get routed through
various process areas, corrosive zones and gets exposed to
seawater, raw water, moist soil, acidic & alkaline fumes, steam
and immersion conditions. Thus making a permanent physical
contact of electrolyte with pipeline external surface leading to
accelerated / aggressive corrosion of metal. In the shown
photographs, in-spite having Conventional epoxy paint on their
surface, metal deterioration along with premature failure of
paint is clearly visible.
CONCRETE CORROSION
Over a period of ageing, concrete being porous in nature,
susceptible for deterioration in the form of erosion, spalling,
cracks when exposed to Seawater, acidic or alkaline liquids or
hot water immersion. Reactions make concrete weak and lose
mechanical strength. Increase of volume of reinforced
corrosion cause external thrust which result in cracks and
accelerate further attacks.

TANKS INTERNAL CORROSION
Internal surface of storage tanks holding DM Water ( is a
highly reactant with mild steel), Acidic solutions / Alkaline
solutions cause mild steel to undergo rapid chemical reactions
to produce oxide layers result in loss of metal thickness.
Addition of temperature of liquid influence accelerated
corrosion of metal surface. Variation of liquid levels also
influence increment in corrosion. More the electrical
conductivity of liquid, more the corrosion over internal surface
of storage tanks.
TUBESHEET & WATER BOX CORROSION
Bi-metallic ( different metals joined physically together i.e.,
tube & sheet ) induce galvanic or bimetallic corrosion in the
presence of highly conductive electrolyte such as Seawater,
acidic / alkaline water with temperature causes deterioration of
less noble metal in the form of pitting and cavitation thus lead
to punctures / leakage of cooling medium with condensate.
Similarly, water box surface is subjected to deterioration due to
heavy impact and turbulent water along with electrochemical
reaction with metal surface.

SALINE CORROSION
Supporting structures, conveyors, tanks, jetty equipment, ship
loaders / un-loaders which are over Sea or nearby sea tend to
react with saline salts in the presence of moisture to produce
corrosion oxide layers. Since the exposure is continuous,
moderate to severe metal loss is expected in very short
periods. Here shown photographs are clearly depicting the
total failure of solvent based paints, conventional epoxy paints
used to protect these structures and at the same time severe
metal loss is also visible.
CLARIFIER / THICKENERS CORROSION
Mild steel rack arms, feed well tank, clarifier well are always
immersed in process water / effluents with wet temperature
subjected to undergo severe chemical corrosion and result in
loss of thickness and hence mechanical strength. In addition
to chemical corrosion attack, if handling liquid contains
suspended particles, they cause abrasion of metal. Abrasion
and corrosion are inter-linked and aggravates metal
deterioration. In these immersion conditions, general epoxy
based paints will never yield and lead to failure as well as
corrosion of thickener / clarifier mechanism.

STRUCTURES CHEMICAL CORROSION
Supporting structures of plant equipment, pipelines installed in
chemical ambience are prone to higher degree of corrosion
due to exposure of steam, chemical fumes, water spills, high
humid conditions.
Multiple layers of corrosion making loss of metal thickness and
hence mechanical strength. At these exposure conditions,
solvent based paint systems are unable to resist and protect
metal, in turn they aid underneath corrosion of metal.
BAG HOUSE CORROSION
Flue gases handled by bag houses in process plant contains
SOx, NOx and temperature. Ingress of false air or moisture
facilitate formation of condensed sulphuric acid over metal
surface of bag house and doors leading to chemical corrosion
of metal.
Permanent deposition of chemical soaked mud or dust with
moisture becomes a permanent source for electro-chemical
reaction of metal.

ELECTRIC SUBSTATION STRUCTURES
CORROSION
Mild steel or Galvanized iron supporting structures supporting
CT, PT, MOCB, LA, Bus, Conductors etc which are located in
saline atmosphere, industrial polluted zones suffer from
chemical corrosion thus leading to gradual deterioration of
metal thickness. Shown photographs are clearly depicting the
total failure of solvent based paints, conventional epoxy paints
used to protect these structures and at the same time severe
metal loss is also visible.
STORAGE TANKS EXTERNAL CORROSION
At some areas, compared to internal corrosion of tanks,
external corrosion is higher due to their exposure to moisture /
steam / acidic / alkaline fumes / chemical spills etc. Corrosion
is aided by metal temperature.
Moderate to severe degree of corrosion in the form of pitting /
uniform is observed at many industries even though tanks are
protected with conventional epoxy based paints.

ELECTRIC TRANSMISSION TOWER CORROSION
Mild steel or Galvanized iron transmission towers of 33kV /
66kV/ 132kV / 220kV or even 400kV ratings which are located
in saline atmosphere, industrial polluted zones suffer from
chemical corrosion thus leading to gradual deterioration of
metal thickness. Zinc tend to react with SOx, NOx and results
in zinc runoff from galvanized iron tower parts. Use of solvent
based paints, conventional epoxy paints used to protect these
structures are not able to meet the desired protection in terms
of retaining structural dimensional stability.
PITTING / CAVITATION / EROSION OF
SCRUBBER VESSELS
Shown photographs are extreme metal loss of scrubber
vessels which are handling various process mediums contains
chemical, temperature as well as abrasive substances.
If not protected in a proper way, metal loss from 1 mm to even
13 mm in irregular or localized pattern is practically observed
in many industries.

ProCoat Experience
Versatile Applications Were Executed By ProCoat Specialities Pvt. Ltd., With ProCoat Range Of
Advanced Polymer Coating Systems In Various Industries
Carried Out Maintenance & Protection Solutions Such As
 Metal Reclamation
 On-Line Oil Leakage Arresting
 Condenser Tube Sheet & Water Box
 Electricity Transmission Towers
 Electricity Substation Structures
 Storage Tanks External
 Storage Tanks Internal
 Pipeline External
 Pipelines Internal
 Pump Internal
 Pump Impellers
 Pump Base Frames & Motor Externals
 Vertical Turbine Pumps
 Plant Structures
 Ship Loader / Un-Loaders
 Saline Protection
 Process / Flue Gas Scrubbers
 Concrete Protection
 Thickeners & Clarifiers
 Process Equipment
 Bag House Doors & Internals
 Chimney / Stack Internal

Metal Reclamation
Shafts, bearing housings, pump casings, motor end
plates, condenser tube sheets, water boxes, scrubber
vessels, impellers etc.. generally suffer from wear, tear,
pitting and cavitation problems and at most of the
places, welding is not suitable and recommended on
account of deformation problems with metallurgy.
ProCoat has solution to reclaim and rebuilding of metal
parts by ensuring optimum mechanical strength,
corrosion resistance along with temperature resistance
thus meeting requirement of regaining the profile of
worn out parts.
Reclamation of Metal Parts in seawater, chemical
immersion conditions to get a dependable repair by
 Rebuilding of worn out Shafts
 Restoring of worn bearing housings
 Valves Repair
 Rebuilding of pitting, cavities in Condenser Tube
Sheet
 Reclamation of deteriorated pump impellers
 Water box metal rebuilding
 Scrubbers internal surface
 In-situ repair of pump casing, collars
 Resurfacing of baffle plates

Oil Leakages from
 bottom & top bell covers, flanges, bolts,
 weld joints, drain plugs,
 radiator weld joints,
 glass indicators,
 conservator tanks,
 valves, buchholz relay,
 cementing joints
and other areas can be arrested by ProCoat products
and method. At the same time, as a preventive method,
flexibilized, temperature resistant and anti-ageing
gaskets can be made to prevent oil leakages at the time
of overhaul.
On-Line Oil Leakage Arresting
In general, in oil filled equipment such as transformers,
reactors, MOCBs gaskets tend to age due to variations
in metal and oil temperature, exposure to moisture and
corrosive ambience lead to induce oil leakage from bell
covers, bolts, weld joints, flanges etc. ProCoat
products are designed to attend this problem without
“draining oil” from equipment with its advanced
leakage repair products ON-LINE even when oil is
oozing.
Leakage arresting works executed by ProCoat lasting
for almost 9 years.

Condenser Tube Sheet & Water Box
ProCoat 100% solids, solvent free,
high functionality Novolac Epoxy
coatings filled with ceramic,
carbide along with many modifiers
are engineered with exceptional
strengths attaining barrier
properties, permeation resistance,
Galvanic corrosion i.e., bi-metallic corrosion of tube sheet
is a common corrosion phenomena at the interface of
tube & sheet in condensers when exposed directly to
conductive electrolyte such as raw water, seawater or any
other process medium. Deterioration of less noble metal
leads to formation of pitting which gets aggravated to
cavities around periphery of tubes which cause leakage of
cooling medium into condensate thus making whole
function of condenser come to a stand still.
Pitting and cavitation formation
over water box & doors surface is
also a well noticed problem which
cause more turbulence inside
water box.
flexibility, immersion temperature resistance, undercut
resistance, adhesion strength, nil shrinkage, high build
film properties, abrasion, impact resistances etc makes
the coating ideal, dependable to meet protection
requirements of condenser tube sheet as well as water
boxes in various cooling media such as raw water,
seawater, oils, acidic or alkaline mediums.

Electricity Transmission Towers
ProCoat,
advanced
solvent free polymer coatings and
quality surface cleaning system
i.e., sand blasting of transmission
towers prior to coating
implemented over various towers
yielding absolute protection
performance from past 8+ years
by ensuring structural
dimensional stability without any
underneath corrosion of metal.
Conventional red oxide + aluminium, zinc based epoxy
paints being used generally for the protection of electric
transmission towers running through coastal and
industrial zones (atmospheric categories : ISO 9223 C4,
C5-I, C5-M & CX) are observed with total deterioration in
very short spans along with loss of metal thickness
leading to gradual replacement of
members and total towers. Even
galvanized iron towers undergo
rapid “zinc runoff” from the
surface due to reaction with
industrial pollutants such as SO2,
NOx & moisture.

Electricity Substation Structures
ProCoat, advanced solvent free polymer coatings and
quality surface cleaning system i.e., sand blasting of
mild steel structures in substation prior to coating is
implemented over various parts yielding absolute
protection performance from past 8+ years by
ensuring structural dimensional stability without any
underneath corrosion of metal.
ProCoat Specialities has expertise in protection of
both Mild Steel & Galvanized Iron structures of
132/33kV & 33/11 kV substations located in most
critical chemical, saline and corrosive zones of
electricity boards.
Conventional red oxide + aluminium, zinc based epoxy
paints being used generally for the protection of
substation’s equipment supporting structures such as
CPL, Isolator, Breaker, Vertical Towers, Booms which
are located in coastal and industrial zones
(atmospheric categories : ISO 9223 C4, C5-I, C5-M &
CX) are observed with total deterioration in very short
spans along with deterioration of mild steel metal
thickness leading to gradual replacement. Even
galvanized iron parts are undergoing rapid “zinc
runoff” from the surface due to reaction with industrial
pollutants such as SO2, NOx & moisture.

Storage Tanks External
DM Water Tanks, Bulk Acid, Bulk
Alkali Storage Tanks, AVGF Tanks,
Compressor Tanks, Ventilation
Tanks, Process Tanks etc are being
protected by ProCoat, 100% solids,
solvent free high performance
Novolac epoxy coating systems
designed with excellent chemical
resistance, barrier properties,
undercut resistance along with
optimum mechanical strengths to
make coating tough, dependable
for extended periods.
Salinity, chemical ambience,
chemical spill, steam exposure,
water spill, splashes of process
media, gaseous exposure
conditions are generally seen in
process areas causing rapid
deterioration of conventional
epoxy based paints applied over
storage tanks leading to gradual
metal deterioration as well
punctures due to localized pitting
corrosion.
Applied ProCoat coatings are
performing from past 10+ years.

Storage Tanks Internal
Versatile operating conditions prevailing in storage,
process tanks at industries is leading to faster and
accelerated deterioration of metal due to chemical
attack, abrasion and corrosion under moderate
temperatures of chemicals, DM water, sludge, process
media etc.
ProCoat engineered high performance 2.8 to 3.6
functionality Novoalc coatings offers dependable, long
term solution to address this problem by resisting the
chemical attack, preventing the permeation and
ingress of chemicals by means of barrier protection.
High end coatings with un-compromised application
procedure is meeting the long
term protection in many
industries thereby extending the
life of tanks by avoiding
repetition of coating from past
5+ years.
ProCoat high performance,
advanced polymer coatings are
designed to offer optimum
protection to storage tanks
internal from the operating
conditions such as
 Sludge agitation, Sulphur solution storage
 Ammonia storage
 Hydrochloric Acid, Sulphuric Acid
 Sodium Hydroxide
 Abrasive process medium
 Oil and petrochemicals storage, LRS Tanks
 Process tanks and others at moderate temperatures

Pipeline External
Pipelines being an important equipment in any industry
to carry fluid, gases and to be routed through various
process environment get affected with the corrosion
phenomena. External surface of the pipelines are
subjected to
 chemical vapours, chemical splashes,
 water spills, Continuous water immersion
 Submerged conditions, steam exposure,
 heat and many other mixed corrosive materials.
It is observed that conventional epoxy based paints are
failing in very short spans and leading to moderate to
severe corrosion over pipelines
Regular maintenance & replacement is extremely
difficult due to their mountings, elevations and
operational conditions. A long term absolute chemical
corrosion protection with ProCoat coatings are being
opted by reputed industries who tried and failed with
conventional epoxy paints.
ProCoat has versatile experience in protection of
pipelines such as
 Cooling water headers, Gas handling pipelines
 Pipelines in pump house, Hot water pipelines
 Sludge carrying pipelines, Process pipelines
Applied ProCoat coatings are offering absolute protection from past 7+ years
external surface in turn leading to
punctures.

Pipeline Internal
Abrasion, Erosion and Chemical corrosion generally
occur over internal surface of process pipelines
handling corrosive slurry, gaseous medium, raw
water, seawater or corrosive liquids. These interlinked
reactions cause the metal to deteriorate at faster
pace. More the abrasion, more is the corrosion and
vice versa.
ProCoat, 100% solids, 2.8 to 3.6 functionality Novolac
epoxy coating systems are designed to address
abrasion, erosion and chemical corrosion reactions
as thoroughly applied coating forms a tough, high
strength lining over internal surface of pipelines.
corrosion and abrasion problems of pipelines handling seawater, raw
water, effluents, sulphur solutions, gaseous slurry and abrasive and
corrosive process media.
Chemistry of ProCoat lining systems effectively resist
the permeation of chemical / water molecules for
extended periods as the coating isolates metal from
physical and electrical contact of medium for
extended periods. On inspecting despite experiencing
unavoidable mechanical damage, the applied coating
limits the damaged portion without allowing
propagation of corrosion beneath coating, thus
protecting remaining coated surface from the past 7+
years. ProCoat coatings are effectively addressing the

Pump Internal
Basic problems such as Abrasion, Cavitation Erosion
and Corrosion faced by pump casings during fluid
handling can be effectively addressed by ProCoat,
solvent free, multifunctional Novolac polymer coatings
and reclamation products filled with ceramic, carbide
and Kevlar fibres that are engineered with optimum
mechanical strengths. ProCoat systems offer absolute
protection to pump casings along with improvement in
out-flow of liquid by reducing the frictional losses
thereby efficiency of pump will be enhanced.
Above shown photographs are protected Pump
Casings / wet areas handling
Raw Water,
Seawater,
Effluents,
Mild chemical solutions
ProCoat has solutions even to chemical and abrasive
material handling pump’s protection.

Pump Impellers
Metal deterioration, cavitation, edge loss, wear problems
of pump impellers during fluid handling can be
effectively addressed by ProCoat, solvent free,
multifunctional Novolac polymer coatings and
reclamation products filled with ceramic, carbide,
zirconium and Kevlar fibres that are engineered with
optimum mechanical strengths. ProCoat systems offer
absolute protection as well as reduce frictional loss and
improves smooth flow.
Various kinds of pump / turbine impellers were
reclaimed and protected with ProCoat systems which
are exposed to
 Moderate Slurries
 Seawater
 Raw water
 Effluents
 Vacuum
 River water
 Moderate chemical solutions

Pump Base Frames, Motor External
Continuous spillage & dripping chemical, water,
corrosive liquid over pump external surface, pump base
frames and even over motor body external surface leads
to severe deterioration of metal and forces for
replacement option. Even though the principle cost is
low, isolation, shutdown and replacement will be tedious
and costly. ProCoat immersion grade high performance
polymer coatings are capable to offer long term
protection to these parts even under aggressive
chemical exposure conditions.
Pump external surface, turbine pump external surface,
pump bases frames, valves and even electrical motors
are protected by ProCoat which are exposed to
 Moderate Slurries
 Seawater
 Raw water
 Effluents
 Vacuum
 River water
 Moderate chemical solutions

Vertical Turbine Pumps
Vertical turbine pumps in power plants are found with extreme rate of
corrosion over external surface due to continuous immersion and internal
surface seen with pitting, cavities and loss of metal due to continuous
operation. ProCoat has hands on experience in offering long term
protection to both internal and external surface of these pumps.
Above shown photos are parts of
vertical turbine pump which are
refurbished with ProCoat metal
reclamation products and then
protected with high performance
barrier cum corrosion protection
coatings.
For several years now, coatings
are effectively protecting these
pumps which are handling both
raw water and seawater.

Plant Structures
ProCoat has hands on experience in protecting different
kind of structures in industries and extended life from past
8+ years where conventional systems are unable to address
aggressive corrosion exposure conditions prevailing in
process areas. Implementation of quality surface
preparation prior to application of high performance coating
is meeting desired protection
requirements.
Above shown pictures are executed works by ProCoat for
the protection of supporting structures of pipelines,
equipment, platforms, process tanks etc exposed to
ammonia, sulphur chemical fumes, saline breeze, industrial
pollutants under variable temperature conditions.

Ship Loader / Un-Loaders
ProCoat established 9+ years of absolute saline corrosion protection to Ship
Loaders / Un-loaders at jetty areas. More than 10,000 sq mtrs surface area of
these equipment in totality is protected by ProCoat advanced, solvent free,
high performance polymer coatings by implementing stringent surface
cleaning, application and quality checking system to meet the expectations of
equipment’s owners. Below shown photographs are interior and exterior
portions of huge ship loader and un-loaders. Various inspections revealed
optimum performance even at mechanically damaged areas without allowing
Undercut corrosion. Top coats are
still in intact condition even after
long periods of saline exposure.

Saline Protection
Coastal Jetty areas, severe saline corrosion is a
common problem and most of structures are being
protected by conventional paints which are unable to
resist the salt attack in turn fail in short periods with
very thorough underneath corrosion of metal. Studies
shows severe metal loss over these costly and critical
installations.
ProCoat has proven performance in ensuring absolute
and optimum saline corrosion protection to metal and
executed many applications in coastal based
industrial plants.
Above shown photographs are protective coating
applications carried out by ProCoat over Jetty area’s
 conveyor structures,
 equipment supporting structures,
 huge hopper supports,
 boiler structures,
 conveyor roller support brackets
 electrical switch yards marshalling boxes.
Irrespective of size and shape of structures, elevation, ProCoat service team
implemented un-compromised surface cleaning, contamination removal,
coating application and quality checking procedure for enhancing life.

Process / Flue Gas Scrubbers
Process vessels & flue / furnace gas scrubbing vessels are subjected to
severe to extreme chemical corrosion due to presence of highly acidic
substances, slurries along with moderate to high temperatures. These
working conditions are extremely favourable for metal deterioration ranging
from 1mm to 15mm localized or uniform metal loss.
More than 20 scrubber vessels were reclaimed and
protected by ProCoat high performance 3 to 3.6
functionality Novolac Polymer systems and many
inspections have revealed optimum protection from past
7+ years.
Top gas, Cooling Gas, Excess Gas Mist separators,
Venturi Scrubbers, Packing scrubbers etc are protected
by ProCoat systems.
Applied ProCoat systems are addressing
 Abrasion force of scrubbing medium
 Resisting the permeation of corrosive chemicals
 Resisting the cold wall effects and osmotic blistering
 Withstanding cyclic variations in temperatures
 Preventing the propagation of pits and cavities.

Concrete Protection
Concrete being porous in nature, is more susceptible
for chemical attack specifically in process areas, DM
plants, Chemical containment areas and even storage
tanks. Preventive measures as well as protection
measures both are mandatory to avoid structural /
mechanical strength failures in such areas.
ProCoat has experience in addressing these chemical
corrosion problems of concrete substrate with solvent
free, low viscosity primers along with chemical
resistant top coats to prevent permeation of chemicals
into concrete surface.
ProCoat coatings are performing effectively and
meeting concrete protection at
 Pump concrete foundations
 Effluent trenches
 Bases of chemical tanks
 Primary containment areas
 Secondary containment areas
 Chemical treatment areas
 Storage Tanks
 Process floors / Cooling Tower Sluice Gates
 Soft water / raw water / cooling water ponds /
Fore-bays
And many other process areas where concrete
structures are present.

Thickeners & Clarifiers
Continuous hot liquid immersion, suspended particles,
abrasive erosion and chemical corrosion of metal
structures inside clarifiers and thickeners is a common
problem being observed in many process industries
which results in loss of angle and body thickness and
eventually forced to replace parts or in totality over a
period of time.
ProCoat coating systems are proven in this area from
past 6+ years without allowing any corrosion over rack
arms, feed well tanks, inlet pipelines and effectively
enhancing equipment life.
Depicting images are ProCoat protected Clarifiers,
Thickeners which are handling corrosive, abrasive
sludge and plant’s process liquids.
ProCoat team implement international standards in
surface cleaning, contamination removal, coating
application and relevant quality checks during and after
application helping to achieve desired protection
requirement to clarifiers & thickeners.
Products and application methods will be selected
based on exposure and operating conditions for better
protection planning.

Process Equipment
ProCoat has hands on experience in application of
coating systems over high rise process equipment
& structures having elevations of 50+ meters by
implementing standard surface cleaning & quality
application methods and achieved absolute
performance from past 8+ years
Shown photos are of primary gas coolers, gas
towers, scrubber vessels, decomposition boilers,
steam fans, stacks, flayer gas structures and huge
chemical storage tanks which are protected from
the exposure of ammonia, sulphur, steam and
industrial pollutants.

Bag House Doors & Internals
In cement industries and power plants, bag houses are most important
equipment in process. Precipitation of sulphuric acids on internal surface of
bag house and doors under high temperature causes chemical corrosion
thus leading to punctures and metal thickness loss.
ProCoat engineered coatings have been addressing
chemical attack, high wet and dry temperatures,
abrasion problems occurring over internal surface of
bag house.
Above shown photos are of protected bag house internal walls & doors to
address sulphuric acid corrosion under high temperature operations along
with abrasion and impact forces of dust particles.
Records shows 8+ years of absolute protection performance of applied
ProCoat coating systems without allowing corrosion of metal.

Chimney / Stacks Internal
Flue gas / granulation chimneys internal surface
undergo severe degree of corrosion due to
chemical attack, abrasive action of suspended
particles, high temperature, altering wet
conditions during operation.
ProCoat high performance 3 to 3.6 functionality
Novolac epoxy coatings filled with ceramic,
carbide, zirconium fillers have been offering
long term protection to internal surface of
chimney / stacks by effectively resisting the
chemical and abrasion even under variable /
cyclic temperature operational conditions.
Images depicted are of granulation chimneys
having elevation of 55+ meters which were
protected internally by ProCoat systems with
stringent surface preparation and quality
application methods.
ProCoat coatings are capable to address
sulphur, nitrous oxide and other chemicals
generally found in flue gases and granulation
systems.

Hydro Power Plant Equipment
Hydro power plants equipment such as Pelton wheel, Francis Turbine,
Kaplan Turbine, Spiral Casing, Steel Housings, Penstock Internal,
Guide Vanes etc are subjected to corrosion, abrasion due to acidic
nature of handling water along with suspended silt.
Protection of these wet parts with high performance, abrasion &
corrosion resistant polymer coatings will enhance the life and protects
from pitting, cavitation and corrosion problems.
Dam gates which are always submerged in
water undergo corrosion and conventional
paint systems are unable to resist the
permeation of water hence induce
corrosion. A barrier lining is a long term
solution to these critical equipment

ProCoat Performance Evaluation
Some of critical applications carried out by ProCoat were periodically inspected to evaluate applied
coating performance and achieved metal protection.
Primary purpose :
 Coating’s ability to resist the attack of exposed ambience / handling medium
 Adhesion of coating with substrate
 Changes in surface texture of coating on account of reactions with exposed medium
 Ability of coating to resist the undercut corrosion
 Retention of dimensional stability of parent substrate
 Ability of coating to protect substrate even applied to localized portions of equipment
 Achieved protection performance periods
 Expected further life of coatings based on present observed condition on substrate
 Learning for improvisation for future works
 Arriving cost economics per square meter / per year / Expected life

Corrosive Slurry Handling Duct Internal
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Handling : Abrasive, Corrosive & Chemical Slurry With 50+ deg C temperature
Coating Applied In : 2007 Coating Inspected In : 2012 Period Of Observation: 5+ years
After a period of 5 years, during 2012 capital repair, some of
these ducts were removed and kept in the yard. ProCoat team,
carried out inspection of these old ducts on 18-11-2012.
Photographs showing the cleaning of old ducts, which
revealed INTACT condition of applied ProCoat coating
pertaining to 2007. Further, coating was intentionally damaged
by chipping, which revealed the “blast cleaned” surface of CG
duct. This indicates, most effective protection offered by
ProCoat coating by absolutely preventing the “INGRESS” of
corrosive medium & resisting the abrasion caused by the
flowing medium on the CG Duct surface.
ProCoat Coating enhanced 5+ years life of CG Ducts with ABSOLUTE
BARRIER PROTECTION without any Corrosion OR Metal Loss Of CG
Ducts surface.
In the year 2007, ProCoat team carried out thorough blast cleaning of
internal surface of CG Ducts and applied ProCoat advanced chemical
and abrasion resistant polymer coating to an average thickness of 500
microns average. Followed by quality checks including coating
thickness, coating integrity by means of DC Holiday Spark Testing to
ensure flawlessness of applied coating.
Based on the Corex-Mech-Maintenance experience, the medium which is
flowing through these CG Ducts is capable to make punctures within a
period of 3 years due to abrasion & severe corrosion of mild steel
surface which forced to replace them in the intermittent shutdowns of
Corex Unit.

Top Gas Venturi Scrubber Internal
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Observations: It is very much clear that, even after 3+ years of operation of TGVS, applied
ProCoat system has been EFFECTIVELY resisting the multiple effects of medium i.e., wet
temperature, impingement of water, chemical nature of medium, abrasive nature of sludge BY
OFFERING AN ABSOLUTE BARRIER PROTECTION TO METAL. It is observed that ProCoat-
2105, prevented the PROPAGATION OF CAVITIES with required mechanical strength.
Throughout this 3 years 6 months, the equipment was safeguarded over RECLAIMED AND
PROTECTED SURFACE by ProCoat System. It is to be noted that, without ProCoat protection,
operating medium inside TGVS is capable to produce around 8-10mm depth of irregular
cavities (in terms of metal loss) over a period of around 8 years. With the applied ProCoat
system, even after 3 years 6 months, there is no sign of corrosion over TGVS conical portion.
It will take lot of time to initially damage ProCoat-1751 coating and then to expose ProCoat-
2105 and further after a long period only entire ProCoat-2105 gets removed before finally
exposing the original TGVS shell surface to the operating medium. Therefore by adopting
ProCoat reclamation & protection system, Scrubber life can be enhanced to extended periods
without the need of any welding or replacement or cladding.
High degree of Corrosion & CAVITATION (irregular
metal loss of TGVS shell) can be seen before the work
was started during April-2009. Around 8-10mm deep
irregular metal loss has taken place in approximately
SIX years of operation.
Fresh water cleaning to remove contamination, Chilled
Iron Grit Blasting with SA2.5 surface finish profile &
Application of ProCoat-2105 to RECLAIM the
CAVITATION as can be seen in the photographs
Application of ProCoat-1751 over the RECLAIMED CONICAL PORTION with ProCoat-2105 inside TGVS
with due quality checks was carried out in APRIL-2009 can be seen in below photographs. Applied
ProCoat SYSTEM is capable to PREVENT THE PROPAGATION OF CAVITATION, as well as for offering
protection from CHEMICAL CORROSION & Abrasion of working medium inside TGVS.

Cooling Gas Packing Scrubber
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
ProCoat Performance after
5 years of observation in 2013
During Corex #1 capital repair in August 2013,
CGPS internal surface was initially jet cleaned and
later Copper Slag Blasted. After blasting, it was
noticed that, the applied ProCoat Metal Reclamation
product & ProCoat chemical resistant coating done
5 years ago was found in good condition without
any sign of corrosion beneath its surface. Metal
surface has been under excellent protection even
with continuous exposure of aggressive corrosive
medium for 5 years of operation.
ProCoat system has been effectively resisting the propagation of cavitation thereby metal
surface getting proper protection without any further deterioration. Previously applied ProCoat
chemical resistant coating was forcibly removed to apply a fresh coating over entire surface of
Cooling Gas Packing Scrubber.
In July 2008, CGPS top side nozzle area portion was blast cleaned
and large cavities were rebuilt with ProCoat metal reclamation
system i.e., ProCoat-2105 and entire surface was protected with
ProCoat-1751 which is a chemical & abrasion resistant coating
system. ProCoat system was adopted to offer BARRIER protection
to metal and to prevent propagation of cavities.
Coating Applied In : 2008 Coating Inspected In : 2013 Period Of Observation: 5 years

Top Gas Packing Scrubber
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
In July 2008, TGPS top side nozzle area portion was also blast
cleaned and large cavities were rebuilt with ProCoat metal reclamation
system i.e., ProCoat-2105 and entire surface was protected with
ProCoat-1751 which is a chemical & abrasion resistant coating
system. ProCoat system was adopted to offer BARRIER protection to
metal and to prevent propagation of cavities.
During Corex #1 capital repair in August 2013,
TGPS internal surface was initially jet cleaned
and carrying out Copper Slag Blasting. After
blasting, it was noticed that, 5 years back the
applied ProCoat Metal Reclamation product &
ProCoat chemical resistant coating was found in
good condition without any sign of corrosion
beneath its surface. Metal here was under
excellent protection even under continuous
exposure of aggressive corrosive medium for
5 years of working.
ProCoat system has been effectively resisting the propagation of cavitation thereby metal
surface was under protection without any further deterioration.
ProCoat Performance after
5 years of observation in 2013

Gas Inlet Cone Heated Surface
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Heated Shell Surface Cooled By Water Making Hot Immersion Conditions
Cooling Gas Inlet Cone external surface was blast cleaned and
protected with ProCoat coating system in September 2008 (as
shown in above photos).
Observation :
During Corex #1 Capital Repair (August
2013) i.e., after 5 years, same Inlet cone
was jet cleaned and further COPPER
SLAG BLASTED. On maximum surface
ProCoat coating was found INTACT
except few areas where surface water
cooling has affected adhesion. It also
became difficult for removal of ProCoat
coating even with high pressure copper
slag blasting. For the past 5 years, CG
Inlet Cone surface was under Substantial
Protection from the given HOT & WET
working conditions.

CO Gas Compressor Suction Silencer Tank Internal
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Same Silencer tank was opened during Corex #1 capital
repair - August 2013 ( i.e., after 5 years). As planned by
Corex Officials to provide ProCoat coating again, entire
surface was water washed and Copper Slag Blasted. It is
found that the applied ProCoat coating 5 years ago was
still in excellent condition and faced difficulty to remove
by Blast Cleaning. This indicates that the coating has
been ensuring absolute Metal Protection for 5 years
without any ingress of corrosive and chemical
substances being handled by CG Silencer continuously.
Medium Exposed : Highly abrasive & chemically corrosive gases with temperature creating hot
Immersion effect continuously on surface
CO gas which is being scrubbed through various scrubbers is collected in this cooling gas
compressor tank to facilitate pumping further. Over metal surface, chemical corrosive sludge
with temperature is always available to induce chemical corrosion. ProCoat implemented very
thorough surface preparation and applied high performance barrier coating to enhance life
from pitting and cavitation effect.

Cokeoven Primary Gas Coolers
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Problem : As shown in the photographs,
external surface of these critical PGC’s in both
Coke Oven 3 & 4 were undergoing rapid and
aggressive chemical corrosion due to
continuous exposure of ammonia vapours,
moisture and other process pollutants, causing
mild steel metal to deteriorate in the form of
localized as well as uniform chemical attack.
Conventional paint system being used is not
yielding any satisfactory results, in spite of
having them on surface, deterioration of metal
was still observed .
Medium Exposed : Ammonia, Sulphur gases with moisture making chemical precipitation
Due to continuous operation of PGC’s, lot of dust, mud and corrosive
substances got settled over coolers which are protected with ProCoat
coating system in August 2011. ProCoat engineer carried out
inspection of applied coating to check its performance as around 4
years are completed after protection. By pouring water and brushing,
accumulated got mud removed from PGC surface and found, ProCoat
coating in intact condition. Very thorough inspection reveals that
applied ProCoat coating is effectively resisting the chemical attack
and preventing the ingress of chemical substances through it thereby
ensuring barrier protection to PGC surface from past 4 years and
expected to last long based on present good condition of coating.

Cement Plant’s Pre-Heater Structure
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Saline Salts, Moisture & Industrial Pollutants Containing SO2, NOx
By doing very thorough blast cleaning, removal of salt
contamination from surface and after second round blast
cleaning to reveal Swedish Sa2.5 i.e., near white metal finish
an average 75 micron surface roughness on surface, applied
ProCoat coating over few horizontal & vertical I Beams inside
Preheater platform in the year 2005 to offer protection from
saline corrosion and humidity. From 2005 to present time,
NCCL applied normal epoxy paint over ProCoat coated area
in routine painting schedules.
During the inspection of this structure on 05-12-2014 i.e.,
after 8+ Years, few rust spots and deterioration over edges
due to mechanical damages might have occurred during
routine maintenance on coating were found at this area. Also
layers of normal paint seen on ProCoat coating. In order to
evaluate the performance, top applied paint layers were
removed with care and seen ProCoat Coating in intact
condition. Further a small area of ProCoat coating was
intentionally damaged to see the condition of metal surface.
Blast cleaned i.e., near white metal finish surface ( surface
prepared in 2005) is found under damaged coating which
indicates “barrier protection being offered by ProCoat coating
system even after 8 years of exposure, at the same time,
ProCoat coating is preventing the propagation of corrosion
and limiting it to damaged portions only (one can see the
above photos to understand this absolute performance of
ProCoat coating).

Ship Loader Complete Surface
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Saline Salts, Moisture & Industrial Pollutants Containing SO2, NOx
This huge Ship Loader having surface area of 3200 sq
mtrs is protected by ProCoat advanced polymer coating with
very thorough surface preparation i.e., blast cleaning, salt
removal from surface along with a yellow colour coding UV
resistant coat and completed protection work in the month of
March 2007.
Coating Inspected in December 2014 : During inspection of this
ship loader, carefully removed the cement deposits from the
surface by wire brushing and water cleaning over 15-20 different
places on ship loader surface and found beneath yellow colour
coating is in INTACT condition. After 7+ years of saline salts
exposure, no deterioration is noticed even on top coat. Under
this ProCoat coating is in excellent condition and expected to
offer protection for more than 12+ years. In order to check the
surface, both yellow colour coat and ProCoat coating were
removed by mechanical chipping at few places and found blast
cleaned surface which was prepared 7+ years ago without any
sign of rust spots and corrosion propagation beneath coating is
preventing effectively.

Cooling Water Header Pipeline
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Continuous water spill & corrosive mud deposition over hot water header
Cooling tower header pipelines & AVGF connected hot water
pipelines were applied with ProCoat advanced polymer coating
system after blast cleaning the surface, adhering to quality
standards.
Heavy mud and dust got settled over surface of pipelines during
operation in a span of 4 years. ProCoat engineers cleaned with
water and wire brushing to check the coating condition.
Previously applied ProCoat coating is found in EXCELLENT
CONDITION even under continuous immersion effect from almost 8+
years and offering absolute protection to these pipelines.
ProCoat coating’s ability to resist the
permeation of moisture molecules
through it due to its highest cross linking
functionality making it to offer such a
long term protection under continuous
immersion conditions.

Trasmission Tower
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Industrial Pollutants Containing SO2, NOx, Moisture
Demo Coating Applied In : 2006 Coating Inspected In : 2012 Period Of Observation: 6+ years
ProCoat Demo Given
on 06-02-2006
As per observations in the
year 2012 , absolute
METAL Protection By
ProCoat even after 6 1/2
Years ,whereas complete
failure of Aluminium Paint
& severe corrosion of
metal at painted area in
less than 6 years

Substation Structure
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Humidity & Industrial Pollutants Containing SO2, NOx
Demo Coating Applied In : 2007 Coating Inspected In : 2013 Period Of Observation: 5+ years
DEMO GIVEN in
August 2007
At 220/132/33kV
Shapurnagar
Substation
Aluminium Paint
Applied Surface with
thorough cleaning of
Metal
ProCoat,100% Solids
Advanced Polymer
Coating Applied Surface
After 6 months
(one rainy season)
Observed corrosion
on Painted surface
After 6 months
(one rainy season)
Absolute Protection
offering by ProCoat
Final Observation of
Demo
January 2013
Very Thorough
Corrosion of Metal &
complete deterioration
of Aluminium paint
After 5 1/2 years
Absolute Protection
offering by ProCoat

ProCoat Advanced Polymer Coating Applied
Structure in 132kV-Naval Wharf Substation At
APTRANSCO, Visakhapatnam in August 2007
Environment is highly
polluted with saline salts,
sulphur dioxide, oxides of
nitrogen etc
Due to falling of CT over structure, applied ProCoat
coating got damaged mechanically and the mild
steel surface got exposed to the highly corrosive
environment
MILD STEEL UNDERGOING
VERY HIGH DEGREE OF
CHEMICAL CORROSION AT
DAMAGED AREA
Whereas, metal surface beneath the ProCoat
coating is Offering absolute protection even
after a period of 4 years without any sign of
propagation of corrosion from the damaged
edge of coating.
THIS IS THE BARRIER PROTECTION
TO METAL BY PROCOAT
This
observation
was done in
June 2011
Substation Structure
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Humidity & Industrial Pollutants Containing SO2, NOx

Back Wash Filter Internal
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Acidic Water with suspended solids
Heavy scaling as well as chemical corrosion in the
form of pitting and cavitation is a generally observed
problem in Back Wash Filters used in Slab Caster
Cooling Water System in Steel Melting Shop of Steel
Plant. Thorough blast cleaning and application of
ProCoat abrasion resistant, barrier coating system
applied over internal surface in the year 2013.
Back Wash Filter was opened for inspection
(during shutdown of caster) on 06-05-2015. Soon
after opening, entire filter was found coated with
mud. By pouring water and wire brushing the
coated surface, complete mud got removed and
earlier applied ProCoat coating was found in
EXCELLENT condition without any kind of
deterioration or damage. No signs of any
corrosion seen. Coating surface was extremely
smooth and helping towards non accumulation of
mud and facilitated easy cleaning. ProCoat
coating is offering chemical corrosion and barrier
protection to Back Wash Filter surface and
enhancing life from past 2 years.

Structures Exposed Brine
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Acidic Water with suspended solids
Coating Applied In : 2013 Coating Inspected In : 2015 Period Of Observation: 16 months
Near Brine Pit Area, all structures are
undergoing extreme degree of corrosion caused
by direct Salt & Hot Steam exposure and
regularly usage of conventional synthetic and
epoxy paints are unable to withstand the
corrosivity of Brine effect and getting
deteriorated within short spans along with
thorough deterioration of metal is seen with
reduction in its thickness. Shown photograph s
reveal the severe condition of structure.
GFL has given opportunity to protect few structure at this area with ProCoat, advanced 100%
solids engineered coating system. ProCoat service team implemented very thorough blast
cleaning, salt removal from the surface and made a rough, clean, contamination free surface
of structure and applied ProCoat coating system and completed all quality checks in May
2014.
After completion of around 16 months, ProCoat engineer
inspected ProCoat coated structure and made an attempt to
clean the coating by wire brushing and pouring water to remove
the appearing stains from the coated surface. By doing this,
stains of rust from the un-coated surface above the structure
which were getting deposited on ProCoat coating got removed
and found that ProCoat coating is absolute and in intact
condition without any RUST SPOT. Absolute brine protection
and barrier protection is offering by ProCoat coating system.

Process Tank Exposed To 33% HCL Fumes
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : 33% Hydrochloric Acid & Alakali fumes from adjacent chemical area
Due to frequent and premature failure of epoxy paints
within 3-6 months period, tank surface is getting
deteriorated in the form of thick rust layers. ProCoat
adopted very thorough surface cleaning i.e., two
rounds of blast cleaning with chemical contamination
removal and application of ProCoat Novolac chemical
resistant coating system followed by a colour coding
green polyurethane top coat in the year 2013.
After 2 years of continuous 33%
hydrochloric acid and alkaline fumes
exposure, same tank was inspected by
ProCoat service persons by scrubbing
the surface with fresh water to remove
deposited dust and stains.
After cleaning, it is found that even top
coat is in intact condition except slight
shading of colour and beneath this
green colour coat, ProCoat chemical
resistant coating is absolutely in
perfect condition and preventing the
chemical reaction as well as
preventing the ingress of chemical
molecules in barrier method. Based
on the present condtion of coating, it
is expected to offer minimum 8 years
of protection life before it comes to
maintenance.

Process Tank Exposed To 33% HCL Fumes
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : 33% Hydrochloric Acid, Sulphuric Acid & MDC fumes of process
Coating Applied In : 2014 Coating Inspected In : 2015 Period Of Observation: 18 Months
HCL, H2SO4, Methonol and MDC fumes are directly coming in
contact with the external and internal surface of this Skirt in
process area and suffering from severe degree of chemical
corrosion. ProCoat implemented stringent surface cleaning
method by two round of blast cleaning and chemical
contamination removal from surface before application of
ProCoat Novolac chemical resistant coating system followed by a
colour coding top coat as per process codes and completed in
the year 2014.
After 18 months of continuous exposure to the
given highly corrosive chemical fumes, ProCoat
persons checked the coated surface by
scrubbing with fresh water and found applied
ProCoat system is effectively resisting the
chemical attack and offering barrier protection
to metal. With this system, equipment’s
dimensional stability can be achieved without
any surface deterioration.

Regeneration Tower Handling Sulphur Solution
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Sulphur solution with other process chemicals with suspended solids
Coating Applied In : 2013 Coating Inspected In : 2015 Period Of Observation: 30 months
Cleaned the coated surface to the maximum
possible extent and found applied
ProCoat-1911 (around 30 months ago), found
in EXCELLENT condition without any signs of
chemical penetration, bulging, lifting, peeling,
texture deterioration on account of chemical
reaction. In fact coating it RETAINED EDGE
protection without any INGRESS from edge.
ProCoat-1911 is effectively resisting the
chemical ingress and hence parabolic bottom
surface of Regeneration Tower Internal is
under absolute barrier protection. Based on
the present condition of coating, it is
expected to get a life of minimum 5-8 years
before it comes for maintenance stage.
Sulphur solution is being handled by this Regeneration tower and to safeguard
it from a puncture that happened at the bottom of tower, ProCoat advanced
solvent free, 3.6 functionality chemical resistant coating system was applied by
following stringent quality surface cleaning along with all relevant quality
checks on 26-02-2013 to offer long term protection to this highly critical
process equipment.

Steam Fan Casing Chemical Protection
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Hydroflouric Acid with casting powder abrasion
Coating Applied In : 2013 Coating Inspected In : 2014 Period Of Observation: 1 year
Hot steam having continuous wet temperature of 100 deg C mixed
with various casting chemicals, making the steam as extremely
corrosive by forming hydrofluoric acid under high wet
temperature. Suspended particles in the steam flowing at high
speed is causing abrasion over surface within an operation period
of 3 months.
Observations : After an operation of 1 year when inspected, It
is noticed that, due to extreme low friction surface of applied
ProCoat-1911, chemical substance accumulation could not
build up and facilitating the flow of handling chemical and
corrosive medium. It is observed that, there is no coating
deterioration has taken place either in the form of chemical
erosion or abrasion due to flow of medium which always
comes in contact with ProCoat-1911 coating. Coating texture
is in good condition and no localized problems are noticed. No
signs of blistering, pitting or bulging of coating is observed.
Very slight colour change happened and this is quite common
due to pigmentation.

Condenser Tube Sheet
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Corrosive & Acidic water
Coating Applied In : 2010 Coating Inspected In : 2015 Period Of Observation: 5 year
Heavily corroded tube sheet and water box was prepared and
reclaimed with advanced Novolac repair system and further
protected with Novolac polymer coating system to offer barrier
lining for effective isolation of corrosive medium with tube sheet
surface to prevent bi-metallic corrosion in the year 2010.
After a continuous operation of 5 years, during
anoverhaul, ProCoat protected tube sheet was
inspected by doing water washing and found
ProCoat coating in intact condition without any
signs of deterioration and effectively preventing the
bi-metallic corrosion of tube sheet and corrosion
over water box surface. This performance indicates
a dependable solution by ProCoat to address
corrosion problem of condenser tube sheet and
water boxes in any type of medium.

Electrostatic Tar Precipitator - Ammonia Exposure
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Ammonia vapours, humidity and process pollutants
As shown in the photographs, external surface of these critical ETPs in
both Coke Oven 3 & 4 are undergoing rapid and aggressive chemical
corrosion due to continuous exposure of ammonia vapours, moisture
and other process pollutants, causing mild steel metal to deteriorate in
the form of localized as well as uniform chemical attack. Conventional
paint system being used could not yield any satisfactory results and in
spite of having them on surface, deterioration of metal is observed .
ProCoat coating system was applied over these ETP’s in 2011 by
following stringent surface cleaning and quality testing procedure.
After 4 years of continuous exposure of ammonia gaseous and
moisture, ProCoat engineers checked the applied coating by
cleaning the coated surface with detergent and fresh water and
found coating was in intact condition without any sign of
deterioration or even rust spots on coating, based on the present
condition, coating will sustain for 8-10 years.

Gas Pipelines In Chemical Ambience
P
r
o
C
o
a
t
P
e
r
f
o
r
m
a
n
c
e
E
v
a
l
u
a
t
I
o
n
Medium Exposed : Ammonia vapours, humidity and sulphur & process pollutants
Cokeoven gas handling pipelines running in ammonia, sulphur
and humid ambience of process area are undergoing localized and
uniform chemical corrosion as shown above. These pipelines
were blast cleaned, contamination removed from surface and then
protected with ProCoat chemical resistant coating system in the
year 2010 with thorough quality checks to offer long term chemical
protection.
Around 5 years of exposure, these pipelines were
inspected after carrying out water jet cleaning to
remove deposited corrosive mud over them and
found ProCoat coating is in intact condition which is
effectively resisting the chemical attack and offering
barrier protection to these huge pipelines and
enhancing life, based on this condition, a minimum 10
years protection is possible with ProCoat coating at
this chemical ambience.

High Performance Coating Solutions for Metal Protection

High Performance Coating Solutions for Metal Protection

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to High Performance Coating Solutions for Metal Protection

Similar to High Performance Coating Solutions for Metal Protection (20)

Recently uploaded

Recently uploaded (20)

High Performance Coating Solutions for Metal Protection