INVESTMENT
PROTECTION
Corrocoat products provide engineering structures and equipment with long-term and cost-effective protection against corrosion.
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Corrocoat Japan previously provided corrosion protection for a newly manufactured gas blower rotor intended for a gas cleaning system at a chemical plant. The impeller and shaft, with an external diameter of 2.57m and a length of 8m, weighed over 3 tonnes and was destined for installation at a chemical plant aimed at removing toxic gases from various chemical manufacturing processes.
Due to the size of the blower, the team at Corrocoat Japan took 2 weeks to complete the project on-site. Special facilities were constructed for blasting and the application of Polyglass VE and VE Veilcoat to ensure that the equipment had suitable encapsulation from the surrounding environment. As part of the project the large rotor required dynamic balancing prior to carrying out coating quality assurance testing. Corrocoat Japan was specified based on previous corrosion resistance tests conducted by the client and subsequent positive experiences with the refurbishment of existing equipment. The client decided to specify the use of required dynamic balancing prior to carrying out coating quality assurance testing. Corrocoat Japan was specified based on previous corrosion resistance tests conducted by the client and subsequent positive experiences with the refurbishment of existing equipment. The client decided to specify the use of Corrocoat products for new equipment going forward, thereby prolonging the service life from the very start. The efficiency of both the team and the products used led to the client commissioning Corrocoat Japan for further work, securing contracts for 4 units of similar dimensions to date. exceed a further 10 years in service.
An engineer from a power plant in Florida contacted Corrocoat USA to look at two of their coal ash silos that had two different types of failed external wrapping systems. These were located at the base of the silo (which was 90 foot (27.4m) off the ground, causing a cavity that could have allowed valuable coal ash to weep from the bottom of the silo and into the atmosphere. Upon inspection, on Silo 1, the rubber liner was damaged in multiple locations and was leading to concrete deterioration and crevices. On Silo 2, there was a polymer liner that failed at the seam, thereby allowing an ingress of moisture and escape of coal ash. Each silo was 50 feet (15.24m) diameter. The repair included coating and sealing 16 inches (40.64cm) up onto the steel silo and 12 inches (30.48cm) onto the concrete base.
A plan was devised by Corrocoat USA, for the removal of each of the failed wraps, using pneumatic tools, working a portion of the surface from 125 foot (38.1m) using manlifts. The steel substrate was primed using Plasmet ZF, whilst Plasmet ECP was used for the concrete. A layer of multiaxial fibreglass followed and then finished off with an additional coat of Plasmet ZF and a polyurethane topcoat for UV protection. An unexpected problem occurred whilst filling holes with the Corrofill E; there were hundreds of holes ranging from the size of a pinhead to the diameter of a walnut.
Although the silo was said to be depressurised during the operation, the shape and size of the silo created a natural draft and therefore pressure on the silo. After filling about 80% of the holes, the pressure increased on the remaining cavities to the point that pinholes formed in the Corrofill E once placed. It took several passes and significant skill and patience to finally stop all of the air from escaping and fashion the filler to a shape that would allow for effective fiberglass application.
Corrocoat USA solved a difficult and potentially expensive problem. The work carried out by the team is predicted to protect the equipment for the foreseeable future – the life of the plant.
Explore our case studies and discover more about the wide range of global projects we’re involved in and learn how we assist our clients in repairing and protecting their equipment.
In the world of petrochemical processing, unplanned downtime can be both costly and disruptive. When a CO₂ pipeline elbow at a petrochemical plant in the Czech Republic developed a leak, the facility faced the risk of shutting down a section of its operations for several days. Traditional repair methods, such as off-site fixes or full pipeline replacement, would have been expensive and time-consuming. However, thanks to an innovative on-site repair solution using Corrocoat products, a shutdown was successfully avoided.
The pipeline elbow in question was made of carbon steel and had already undergone several unsuccessful coating repair attempts. The persistent leak meant that a more robust, long-term solution was needed, one that could be implemented without taking the system offline.
After an inspection by Corrotech, a customised repair plan was developed. Surface preparation of the elbow was undertaken on-site whilst work got underway with fabrication of a 4 mm thick FRP enclosure, using Corroglass 600 Lamination Resin and Multiaxial Fibre Glass Cloth 600 g/m² in the workshop. Once the elbow was prepared and primed with Corroglass 600 Series, the enclosure was installed around the elbow and filled with Corrofill VE on-site. Strength was further bolstered with an additional layer of 600g/ m² cloth before being coated with Polyglass VEHA.
This composite repair solution successfully sealed the leak and reinforced the pipe elbow, eliminating the need for costly shutdowns or major replacements. By leveraging Corrocoat’s advanced coating and composite materials, the petrochemical plant was able to restore the integrity of the pipeline without interrupting operations.
Find out more about our composite repair solutions for industrial pipelines.
The Challenge: Lifespan extension of industrial fan blades.
With the front edges of a cooling tower fan showing signs of corrosion, as well as general wear and tear, the facility owners sought Corrocoat Japan’s help to restore the fan blades, in order to extend their lifespan. The fans consisted of four variable pitch blades made of epoxy composites with glass fibre reinforcement (FRP) and were hollow in construction. The blades were designed to withstand the hot and humid conditions of a cooling tower. Maintaining the blades’ durability, as well as the aerodynamics, was essential.
The team started with a grinder to remove the corroded blade edges, maintaining as close an alignment to the original shape as possible. The blades were then cleaned and degreased using solvents. Glass cloth and Corrocoat 600 Lamination Resin was applied to repair the severely corroded areas and profile adjustment made using sandpaper, to refine it to its original shape. A layer of Corrocoat 600 Series was then applied for additional endurance.
The ease and speed of applying Corrocoat products on-site to protect against erosion and extend the useful life of the fan blades, motivated the client to request the repair of an additional unit. It also persuaded them to introduce Corrocoat products to other types of equipment within their facilities.
Find out what other interesting projects our global partners have been undergoing here.
For the past two weeks, we had the pleasure of hosting our new licensees from Trinidad, Qualitech Machining Services Limited, at Corrocoat’s Head Office. It was a great opportunity to exchange valuable insights, and showcase why Corrocoat is a global leader in corrosion protection solutions.
We were delighted to welcome Cindy Singh Ramlogan, Industrial Projects Manager and Kamiraj Ramphal, NACE/Superintendent. During their visit, they were introduced to our innovative products and met the Head Office teams driving Corrocoat’s success. From in-depth corrosion theory training, to interactive product demonstrations in the engineering and coating workshops and engaging discussions in our R&D labs and marketing department, the visit was the perfect opportunity for our licensees to fully immerse themselves in Corrocoat’s expertise and capabilities.
The sessions offered an in-depth look into the technical aspects of our products and processes, with a spotlight on our renowned glassflake technology. Discussions focused on how to customise our solutions to address the unique environmental challenges faced by the industrial sectors in the Caribbean.
Cindy, with over 20 years of expertise in the Oil and Gas industry, expressed her admiration for the depth and quality of the technical training sessions, conducted by Douglas Lynch who oversees our technical training. Kamiraj, who brings more than a decade of experience in coating solutions and inspection/supervisory roles, was equally impressed. He highlighted the exceptional quality of Corrocoat’s coatings, having had the opportunity to apply the products first-hand on various projects in the workshop.
Douglas overseeing Kamiraj carrying out composite pipe wrapping Engineering Supervisor, Warren Marks working with Kamiraj – dynamic balancing a coated impeller
Trinidad is a dynamic market, with robust industrial activity in sectors like oil and gas, petrochemicals, and manufacturing. By combining Corrocoat’s proven expertise with our partners’ local market knowledge, we are confident in our ability to deliver innovative corrosion protection solutions that exceed expectations.
This visit marks the beginning of an exciting journey, and we are thrilled to collaborate with our Trinidad licensees at Qualitech to achieve great success. Qualitech was founded in 1995 and is one of the leading mechanical engineering companies in the Caribbean. Together, we’re excited to deliver innovative corrosion protection and drive growth in Trinidad’s industrial sectors.
A huge welcome to our Global Network.
Kamiraj and Cindy being presented with their training certifications by Corrocoat Technical Director, Graham Greenwood Sole
From a leaky-roofed workshop in Leeds to a global presence in over 30 countries, employing in excess of 1000 people globally, Corrocoat has come a long way. As we mark our 50th anniversary, Founder and Chief Executive Charles Watkinson reflects on how it all began—and the incredible journey since.
“In 1974 I was working for a company south of the river in London. I travelled with the waking sparrows on Monday mornings, from my home near Leeds, to Peckham in London to start work at 08:30 and back again on a Friday evening, lodging during the week in Greenwich Village. It worked quite well for six months, but then one weekend in late October I was needed to advise on a project in the Middle East and I could not be contacted. No mobile phones in those days! The following week, my boss told me I needed to move to London and made me a very generous offer to do that, but said if I refused, I would be fired. I thanked him and resigned on the spot. Driving back home I thought how was I going to survive with a large mortgage and two small children to feed. I determined to start my own company.
My wife was not impressed when I told her what had happened and said I should look for another job, but I was determined to go my own road. I contacted an associate I had worked with in a previous company called Glassflake UK Ltd and asked if he would be interested in joining me. He agreed and we looked for premises in which to start work. I chose the name Corrocoat and a week later agreed the rental of a building in Hunslet Mills, just some 400 metres from our current head office. Then on Friday the 22nd of November, set to trying to find work. I had some contacts with BP shipping and knew there were some of their pumps still in limbo from Glassflake UK going into liquidation. They agreed I could refurbish them and work commenced. The early months were fraught, but as each problem arose it was solved, sometimes whilst running around with buckets to catch the rain pouring through the leaking workshop roof.
In early 1975, Noel, my partner who also dealt in antiques, decided he was no longer interested and he was paid out, whilst at the same time Hugh, another previous colleague from Glassflake, discussed joining hands and we became business partners. The company was incorporated a couple of months later and became Corrocoat Ltd. And so the long and winding, sometimes tortuous, sometimes stressful, sometimes hilarious road, began. The company grew and grew, so new premises were required along with employees. The company expanded into the overseas market by one customer: Cunard, insisting we service them in Holland and so the overseas arm began expanding rapidly into other territories; Singapore and South Africa. And here we are today after 50 years, operating in over 30 countries, with a great global network of partners and licensees.
It has been an amazing journey and as more than one person has said, it would have made a good TV series. So, I would like to thank all those employees, some of whom have been with us almost from inception, along with our customers, for aiding me and the company to reach this impressive milestone. Thank you each and every one for your efforts and loyalty in helping reaching this goal.”
“I am also proud to say…THIS IS NOT THE END.”
Corrocoat USA recently exhibited at AMP2024. It was a great opportunity to meet new and existing customers and share a coffee at our stand.
“The exhibition at the AMPP Corrosion 2024 conference in New Orleans, Louisiana was a huge success. We met many new potential customers from all over the world who were interested in our technology and services.
“I expect that the effort will have increased international exposure to our brand and we will close sales from leads and inquiries during the week. A big thanks to all who helped us prepare for the event, including the Marketing department from Corrocoat Ltd, CEO Charles Watkinson and Technical Director Graham Greenwood-Sole who joined us from the UK as well as our staff at Corrocoat USA.”
Josh Tankersley, Corrocoat USA
Corrocoat USA is a prominent provider of advanced anti-corrosion solutions and coatings, serving various industries with high-performance products designed to protect infrastructure and equipment from the detrimental effects of corrosion. Established as a part of the global Corrocoat brand, the company leverages extensive research and development to offer innovative, durable, and cost-effective coating systems.
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Established in 1975, Corrocoat Corrosioneering started specialist pump repairs shortly afterwards and since then it has grown in size and stature to its present day position as a world leader, with the skills and facilities to repair and corrosion protect the largest of pumps. Our dedicated Pump Division offers customers a comprehensive service covering pump refurbishment, re-manufacture, modification and coating for corrosion protection of many types of pumps.
The bespoke nature of the service enables us to respond to individual customer requirements and our ability to provide equipment quickly and to budget are key elements in the service offered to customers.
Corrocoat is based in the UK but has a network of over 30 facilities in 6 continents. Our list of clients includes some of the world’s most respected companies operating in fields as diverse as: mining, oil & gas, chemicals, power generation, waste & water, pulp & paper and marine.
Our ability to combine mechanical engineering with advanced polymer technology allows even severely damaged pumps to be refurbished at a fraction of the replacement cost, often without expensive replacement parts. The use of our advanced materials can prevent the need for expensive metallurgical solutions on new pumps, and substantial efficiency improvements can be achieved by utilising the Fluiglide range of materials.
All pumps & pump parts are repaired where possible in accordance with ISO standards or better, with upgrades in materials and tightening of tolerances to improve pump life, efficiency and performance. Many of these pumps are protected against corrosion using Corrocoat’s tried and tested coatings – the selection of which is dependant on the service environment.
COMPLETION PACK
Every refurbished pump is returned to the customer with its own ‘Completion Pack’ giving assurance to the client that the work has been carried out to the highest standard. This pack contains: performance test data, an internal hydrostatic test certificate and mill certificates for material traceability (if required). Details of all work carried out with relevant photographs are also included.
And just like that, we enter another new year! Following an interesting 2023, and an extremely eventful one from a business perspective; progress was made into new markets. We welcomed overseas partners to the UK for the Corrocoat Global Partner Conference, as well as working with hundreds of new and existing clients both nationally and internationally. We look forward to a great 2024.
Some of you may be aware that this year we are celebrating 50 years since Corrocoat was founded by our CEO, Charles Watkinson. In that time, Charles has been instrumental in expanding Corrocoat in to over 30 countries and employing over 1000 people globally. He has designed engineering repair systems, coatings and coating technology, written numerous technical papers and is the inventor of several patents. With a rich brand history and heritage, we have some very exciting plans to honour the incredible milestone this year… stay tuned.
We also have some very exciting news, as the New Year sees Phillip Watkinson, General Manager/Director promoted to the Managing Director of Corrocoat, and sister company Corroserve.
Phillip first joined the company in 2001. He is fully immersed in all areas of the company, and provides a wealth of knowledge and expertise when it comes to specialist coatings and mechanical engineering.
Graham Greenwood-Sole, previous Managing Director for 20 years, moves to the role of part time Technical Director, overseeing and implementing technical and engineering strategies, to ensure continued business growth and success.
Please join us in wishing Phillip and Graham the very best in their new roles. It’ s a very exciting time here at Corrocoat.
Here’s to a great and prosperous year ahead and continued success.
I’m pleased to share my first message as Managing Director; “The year has started positively for our business as we lay the foundations for a solid year ahead with exciting projects and growth unfolding around the world. In the coming months, we will be taking time to look back at 50 years of Corrocoat supporting industries worldwide. Thanks to the contribution of employees, past and present and our ongoing investment in research and development, we have innovated the coatings industry, successfully providing practical and cost effective solutions to corrosion issues in many countries.
Whilst it’s important to pause, take stock and take time to recognise how far our business has come, it’s also important to look forward. And we have much to look forward to as we grow and increasingly support the global recycle, reduce, reuse agenda – enabling largescale capital plant and equipment to be used for longer. You can read more about some of the more recent project in the coming pages here. “
A thermal power plant in Gujarat, India, required refurbishment and corrosion protection for four vertical turbine pump impellers. The pumps, which were made of super duplex steel and had no prior protective coating, had been in operation in sea-water for approximately 12 to 15 years.
The impellers had developed cracks and mechanical damage over time, which significantly impacted their performance. To address these issues, the client approached our partners in India, Kirloskar Corrocoat Private Ltd (KCPL). KCPL were to provide a comprehensive solution; repairing and rebuilding the blades, as opposed to replacing with new impellers.
Along with sister company Kirloskar Brother Limited; a global leader in pump systems, KCPL were able to offer a turnkey solution to repair the damage to the impeller vanes, using both cold and hot refurbishment methods, followed by DP (dye penetration) and UT (ultra-sonic testing). Polyglass VEHA was then applied, with an overcoat of Fluiglide.
Polyglass VEHA is a cold cured glass flake vinyl ester acrylic co-polymer, which was selected as its properties make it ideal for immersion environments, where superior resistance to chemical attack is required.
Whereas Fluiglide; a cold cured, highly modified chemically resistant, two-pack resin system filled with stabilising enforcement to reduce cold flow characteristics, was used to reduce friction and increase energy efficiency.
Following the mechanical refurbishment and coating work as per ISO 21940, the team carried out dynamic balancing of the impeller. They also successfully resolved the problem of uneven clearances between the impeller and liner, further optimising the pump’s performance and efficiency.
KCPL’s specialist pump refurbishment and coating technology provided an effective and efficient solution for the client, ensuring extended lifespan and improved performance, and significant time and cost savings. The cost to refurbish each impeller was just 30% of the original price of the impeller, not to mention the short lead time to repair, as opposed to the delivery timescales for new impellers.
