Case Study

Case Study – Repair and protection for air cooler water boxes

Case Study
Repair and protection for air cooler water boxes


Power generation industry, UK.

Application date

August 2004.

Scope of work

Due to severe sea-water corrosion leading to leakage, repair and future corrosion protection was essential. Also some mechanical modifications were carried out as specified by client.


Internally: Corroglass 600 series & Vinyl ester glass fabric.
External: Plasmet ZF & cosmetic enamel topcoat.


Motor oil cooling waterbox.

Coating system

  • Internal grit blast to ISO 8501-1 SA 21/2.
  • External grit blast to ISO 8501-1 SA 2.
  • Hand application using specialised techniques to rebuild seven damaged water boxes to provide effective, anti-corrosion protection.
  • Application internally of Corroglass 600 series to achieve a minimum dft of 1.5 mm. Coated across the flange faces and fully spark tested at 19kv and thickness checked.
  • Hand application of Plasmet ZF 150μm, followed by a top coat of enamel cosmetic top coat in customer’s house colours.

Coating credentials

This customer were able to save thousands of pounds, by recycling their old components – which some would have deemed as ‘scrap’.

When the water boxes were re-installed, the customer benefited from the same efficiency that you would get with a new system with the added benefit of excellent corrosion protection – extending the life of the refurbished component.

Corrocoat’s coating and engineering expertise combined.

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