Industrial Floor Coatings · Epoxy Coatings · Polyurea Coatings · Concrete Coatings
Industrial Floor Coatings · Epoxy Coatings · Polyurea Coatings · Concrete Coatings
A fusion-bonded enamel tank required a waterproof lining system to prevent water ingress and deterioration. The client needed a durable and seamless solution for both the concrete floor and the steel wall plates. Additionally, they requested two pricing options—one with the lining applied up to one shell plate in height and another extending up to two shell plates.
Due to contamination concerns, the existing tank surface required thorough preparation to ensure proper adhesion of the lining system. Any remaining bacteria or embedded contaminants could compromise the performance and longevity of the coating.
To meet the client’s requirements, we proposed the application of a 2mm thick polyurea lining system to the tank base, including a return up onto the tank shell. The project was executed with a meticulous preparation and coating process to ensure long-term durability and performance.
We took sole possession of the work area to prevent contamination. The tank floor and shell were high-pressure jet-washed and treated with sodium hypochlorite to eliminate bacteria. The top layer of the concrete floor was then mechanically ground to remove deeply penetrated contaminants and create a roughened surface, in accordance with BS 8204-6, to enhance primer adhesion.
The steel shell required additional preparation. Any loose mastic around bolts and joints was cut back, while the mastic joint between the floor and tank shell was inspected, removed if necessary, and reinstated with a PU jointing compound. To ensure proper adhesion, the tank shell was lightly abraded via abrasive blasting, removing remaining contamination and creating a suitable surface profile.
For priming, the shell was coated with a specially formulated epoxy primer designed for enamel coatings. The concrete floor was treated with a DPM (damp-proof membrane) epoxy primer to prevent pinholes and enhance adhesion. To ensure a clean termination detail, masking and wire trim tape were applied to the shell to prevent overspray and stop water migration behind the lining.
The final stage involved the application of a 100% solids polyurea lining system at a nominal thickness of 2mm. The entire coating process was completed within seven days, with the floor ready for light traffic within 24 hours.
This solution provided the client with a highly durable and seamless waterproof lining, significantly extending the service life of the tank while ensuring long-term protection against water ingress and structural degradation.
