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Corrosion Resistance Coating

Corrosion is a significant challenge for industries relying on metal components, as exposure to moisture, oxygen, and chemicals can cause rust and deterioration. Corrosion resistance coating provides a protective barrier, shielding metal surfaces from these harmful elements. Industries like oil and gas, marine, automotive, and construction benefit immensely from these coatings, as they help extend the life of equipment, reduce maintenance costs by up to 35%, and ensure safety by maintaining structural integrity.

Kirloskar Corrocoat Private Limited offers a range of high-quality solutions designed to protect metal assets in various environments. Their coatings, such as epoxy, zinc, polyurethane, and ceramic, are tailored to specific industry needs. For example, zinc coatings provide sacrificial protection by corroding instead of the metal beneath, while polyurethane coatings offer excellent UV and moisture resistance, ideal for marine or coastal environments. These coatings help industries prevent costly downtime and reduce corrosion-related repairs.

Choosing Kirloskar Corrocoat ensures customized solutions backed by years of expertise. Their eco-friendly coatings offer long-lasting protection, saving companies from unnecessary expenses while promoting sustainability. Whether you're protecting an offshore platform, industrial machinery, or vehicle components, corrosion resistance coating is the ultimate solution for maintaining performance and durability, ensuring that your metal surfaces remain strong and efficient for years to come.

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Impeller coating is an essential investment for industries aiming to enhance the performance and longevity of their equipment. Impellers, vital components in pumps, compressors, and turbines, often operate in harsh environments, facing exposure to abrasive and corrosive materials. Without proper protection, impellers suffer from wear and tear, leading to reduced efficiency and frequent replacements. At Kirloskar Corrocoat Private Limited, we specialize in providing high-quality impeller coatings that cater to various industrial needs. Our coatings offer exceptional corrosion and abrasion resistance, ensuring extended lifespans, improved performance, and significant energy savings. Studies have shown that coated impellers can last up to three times longer and improve efficiency by up to 15%, translating to substantial cost savings in maintenance and energy consumption.

Choosing the right impeller coating involves several critical steps, including thorough surface preparation, precise application, curing, and rigorous inspection to ensure quality standards are met. Kirloskar Corrocoat Private Limited offers a range of coatings, including epoxy, ceramic, and polyurethane, each tailored to specific industrial applications. Our expertise, use of high-quality materials, and commitment to customer support make us the preferred choice for many businesses. Coated impellers in water treatment plants, chemical processing facilities, and power generation industries have demonstrated significantly enhanced performance and reduced operational costs. Trust Kirloskar Corrocoat Private Limited to provide the best impeller coating solutions, ensuring your equipment's optimal performance and durability, keeping your operations running smoothly and efficiently.

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Comprehensive Pipeline Coating Solutions by Kirloskar Corrocoat

Pipelines serve as the vital lifelines of various industries, ensuring the smooth flow of essential resources like oil, gas, water, and chemicals. However, just as cholesterol can clog human arteries, corrosion can wreak havoc on pipelines, leading to costly repairs, downtime, and potential safety hazards. At Kirloskar Corrocoat Private Limited (KCPL), we offer high-performance epoxy glass flake, vinyl ester glass flake, and polyester glass flake coatings to combat these corrosion issues effectively. With extensive experience in protecting hundreds of kilometers of pipework annually, KCPL utilizes advanced coatings that provide exceptional chemical and temperature resistance, mechanical strength, and low solvent emissions, ensuring long-lasting performance in even the most challenging environments.

KCPL employs a range of specialist application techniques to ensure high-quality finishes and reduced downtime. These include the pipe spinning method for smaller diameters, the pipe sprayer method for medium-sized pipes, and the airless spray method for larger diameters. Our coatings and linings provide robust protection for various pipeline components, both internal and external, such as pipe spools, elbows, manifolds, and caissons. The use of glass flake-filled coatings ensures that the metal surface is isolated from corrosive media, significantly reducing moisture vapor permeation and extending the coating's lifespan beyond conventional systems. Trust Kirloskar Corrocoat for superior pipeline coating solutions that safeguard critical assets, reduce maintenance costs, and enhance operational efficiency.

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Advanced Corrosion Protection for the Steel Industry with Kirloskar Corrocoat

Kirloskar Corrocoat is a leader in providing long-term corrosion protection using advanced heavy-duty glass flake technology products. Our cutting-edge solutions are designed to extend the lifespan and efficiency of vital equipment in the steel industry. With a team of well-trained engineers and applicators, we are confident in our ability to protect a wide range of assets from corrosion, ensuring their longevity and optimal performance.

Our comprehensive corrosion protection services are tailored to the specific needs of the steel industry, covering essential components such as CW system components, pumps, pipes, valves, water boxes, and gas cleaning plant components. We also specialize in safeguarding ETP components, stove domes, hot air lines, and both insulated and direct atmospheric exposed vessel lines and structures. Our expertise and state-of-the-art technology ensure that these critical assets remain protected from the harsh environments they operate in, significantly reducing maintenance costs and downtime.

By choosing Kirloskar Corrocoat, you are investing in a future where your steel industry assets are shielded from corrosion. Our heavy-duty glass flake technology products provide unmatched durability and resilience, making them the ideal choice for long-term protection. Trust in our experience and commitment to excellence to keep your operations running smoothly and efficiently.

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Fluiglide system- Kirloskar Corrocoat Private Limited

In today's world, where efficient use of energy resources is more critical than ever, innovative coating technologies have emerged to enhance the performance of pumping systems across various industries. These systems are essential in power generation, cooling water systems, the process industries, and water and waste treatment. Among the leading pioneers in this field is Kirloskar Corrocoat Private Limited, in collaboration with Corrocoat, who have developed the groundbreaking Fluiglide system. Since its introduction in 1985, Fluiglide has revolutionized the way industries approach pump efficiency. Applied to thousands of pumps worldwide, Fluiglide has consistently demonstrated significant improvements in efficiency. Extensive testing and evaluation by major manufacturers, utilities, and industrial users have validated the remarkable performance of this system.

The Fluiglide system has been successfully applied in a range of settings, showcasing its versatility and effectiveness. In power plants, Fluiglide helps maximize pump performance in cooling water systems, ensuring efficient cooling and reducing energy consumption. For process industries such as chemicals and pharmaceuticals, Fluiglide coatings improve pump efficiency, leading to smoother operations and lower energy costs. Municipalities and industrial facilities benefit from Fluiglide's ability to enhance the performance of pumps in water and waste treatment plants, ensuring reliable service and reduced maintenance. By reducing friction within pumps, Fluiglide minimizes energy losses, allowing more efficient fluid movement. This results in significant energy savings, which are critical in today’s eco-conscious environment.

In addition to boosting efficiency, Fluiglide's corrosion barrier is a game-changer. Corrosion can severely impact the performance and lifespan of pumping systems. By protecting against nodular growth and surface corrosion, Fluiglide ensures that pumps maintain their performance over time. This protection is particularly important in harsh environments where corrosive substances are prevalent. Fluiglide’s dual benefits of increased efficiency and effective corrosion protection make it a valuable asset for industries seeking to optimize performance and reduce costs. As industries continue to prioritize energy efficiency and equipment longevity, adopting advanced solutions like Fluiglide will be crucial. Embrace the power of Fluiglide and experience the benefits of friction-reducing, energy-efficient protective coatings today.

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Revolutionizing the Water Industry with Kirloskar Corrocoat

The water industry faces significant challenges, including erosion, corrosion, chemical attacks, and mechanical damage to critical equipment. Kirloskar Corrocoat Private Limited addresses these issues with advanced coating solutions, particularly their Fluiglide system. This system enhances pump efficiency and reduces energy costs by minimizing friction and wear. Kirloskar Corrocoat’s coatings protect vital components like valves, pipework, and water treatment tanks from corrosive substances and mechanical stress. Their specialized coatings extend the life of primary settlement tanks, storm tanks, final settlement tanks, and sludge holding tanks, ensuring optimal performance and reducing maintenance costs.

In addition to these applications, Kirloskar Corrocoat offers solutions for structural components such as foot bridges, pipe bridges, and piling, which are exposed to harsh environmental conditions. Their coatings prevent corrosion and mechanical damage, significantly extending the lifespan of these structures. The company also provides specialized coatings for flash mixers, concrete settlement tanks, alum tanks, incinerator effluent tanks, drainage gullies, and mixing bed repairs. By partnering with Kirloskar Corrocoat, clients benefit from enhanced performance, reduced downtime, and cost savings, ensuring the longevity and efficiency of their water and waste management systems.

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Kirloskar Corrocoat: Long-Term Protection for Oil & Gas

Kirloskar Corrocoat boasts an impressive track record of delivering high-quality, long-term, and cost-effective solutions to the oil and gas industry. With a wealth of experience and a deep understanding of industry needs, we have consistently provided our clients with exceptional service and unparalleled results.

Our success in the oil and gas sector is attributed to our advanced glass flake linings, which offer superior protection against corrosion and wear. These linings are engineered to withstand the harshest environments, ensuring the longevity and reliability of critical infrastructure. Our commitment to quality is evident in every project we undertake, from initial consultation to final application.

At Kirloskar Corrocoat, we pride ourselves on the expertise of our trained and skilled application teams. Our technicians are equipped with the latest tools and techniques, enabling them to apply our advanced coatings with precision and efficiency. Their meticulous attention to detail ensures that each application meets our stringent quality standards, providing our clients with the best possible protection for their assets.

Moreover, our comprehensive mechanical and chemical engineering capabilities set us apart from the competition. We understand that each project comes with its unique challenges, and our team is adept at developing customized solutions that address specific client needs. Whether it's protecting pipelines, storage tanks, or other critical components, our coatings are designed to deliver optimal performance and value for money.

Kirloskar Corrocoat's dedication to innovation and excellence has made us a trusted partner for many companies within the oil and gas industry. Our advanced glass flake linings, combined with our skilled application teams and robust engineering capabilities, ensure that our clients receive the highest level of protection for their investments. We are committed to providing solutions that not only meet but exceed industry standards, helping our clients achieve long-term success and operational efficiency.

In conclusion, Kirloskar Corrocoat stands as a leader in providing durable, cost-effective, and high-performance coating solutions to the oil and gas sector. Our proven track record, coupled with our advanced technologies and expert teams, underscores our commitment to delivering value and excellence in every project. By choosing Kirloskar Corrocoat, companies in the oil and gas industry can trust that their assets are in capable hands, protected by the best coatings available in the market.

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Coating Application Techniques- Kirloskar Corrocoat Private Limited

Our application process begins with thorough surface preparation, a critical step that involves cleaning, degreasing, and mechanically or chemically treating the surface to ensure maximum adhesion of the coating. By removing contaminants and creating an ideal substrate, we enhance the performance and durability of the applied coatings.

Following surface preparation, our highly trained technicians apply the coatings using advanced techniques tailored to the specific requirements of each project. Whether it's spray application, brush, or roller methods, we ensure uniform coverage and optimal thickness to achieve the desired protective properties. Our coatings include a variety of materials such as epoxy, polyester, and vinyl ester glass flake coatings, each selected based on the specific environmental challenges and operational demands.

Quality control is integral to our process. At every stage of the application, we conduct rigorous inspections and tests to verify the integrity and effectiveness of the coating. This includes checking for proper adhesion, thickness, and uniformity, as well as conducting environmental exposure tests to ensure the coating will perform as expected in real-world conditions.

Upon completion of the coating process, all items treated with our Kirloskar Corrocoat product range undergo a final quality assurance check. This comprehensive evaluation ensures that every coated piece meets our high standards and the specific requirements of our clients. Only after passing these stringent tests is a quality assurance certificate issued, signifying that the coated infrastructure is ready for deployment with the confidence of long-term protection against corrosion.

In addition to our meticulous application process, we offer ongoing support and consultation to our clients. This includes guidance on maintenance practices and reapplication schedules to ensure continued protection and performance of the coatings. Our goal is not just to apply a coating, but to provide a complete corrosion protection solution that enhances the lifespan and functionality of vital infrastructure.

At Kirloskar Corrocoat Private Limited, we take pride in our ability to deliver high-quality, reliable anti-corrosion solutions. By leveraging our expertise, state-of-the-art technology, and commitment to quality, we help our clients protect their investments and ensure the safety and efficiency of their operations. Our protective coatings are more than just a barrier against corrosion; they are a testament to our dedication to excellence and our role in building a more resilient and sustainable industrial landscape.

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Maximizing Efficiency and Longevity in Gas Cleaning Plants with Internal Coatings

Gas cleaning plants play a crucial role in industrial processes by removing harmful pollutants from gases before they are released into the atmosphere. However, the harsh conditions inside these plants can cause significant wear and tear. This is where GCP - Gas Cleaning Plant internal Coating comes into play. In this blog, we'll explore the benefits of internal coatings and how Kirloskar Corrocoat Private Limited can help protect and enhance your gas cleaning equipment.

Why Internal Coatings Are Essential

Gas cleaning plants face numerous challenges, including:

- Chemical Corrosion: Exposure to various acids and alkalis. - Erosion: Continuous flow of abrasive materials. - Temperature Fluctuations: High temperatures that can weaken materials over time.

These factors can lead to frequent breakdowns, reduced efficiency, and increased maintenance costs. Internal coatings provide a protective barrier that extends the life of the equipment and maintains optimal performance.

Benefits of GCP - Gas Cleaning Plant Internal Coating

1. Corrosion Resistance - Protects against chemical attacks. - Extends the lifespan of the equipment.

2. Erosion Protection - Shields internal surfaces from abrasive particles. - Reduces wear and tear.

3. Temperature Resistance - Withstands high temperatures. - Maintains structural integrity.

4. Improved Efficiency - Ensures smooth operation. - Reduces downtime and maintenance costs.

5. Cost Savings - Lowers maintenance and repair costs. - Reduces equipment replacement frequency.

Kirloskar Corrocoat's Expertise

Kirloskar Corrocoat Private Limited, based in India, is a leader in providing high-quality internal coatings for gas cleaning plants. Our coatings are specially formulated to meet the unique challenges faced by these systems. Here’s how we make a difference:

- Tailor-Made Solutions: Custom coating solutions for specific needs. - Advanced Technology: Coatings offer superior protection and durability. - Experienced Team: Skilled professionals ensure maximum coverage and protection.

Key Features of Our Internal Coatings

1. High-Performance Polymers - Excellent resistance to corrosion and erosion. - Designed for harsh chemical environments and high temperatures.

2. Biofouling Prevention - Prevents the growth of unwanted organisms.

3. Cathodic Disbonding Resistance - Ensures long-term durability.

4. Crack Bridging - Maintains the integrity of the protective layer.

5. Graphite Flake-Filled Composites - Offers high conductivity and chemical resistance.

6. Sulphuric Acid Resistance - Understands high concentrations of sulphuric acid.

7. Repair Compounds - Fixes damaged areas, extending the life of the existing coatings.

Application Process

Applying internal coatings to gas-cleaning plants involves several steps:

1. Surface Preparation - Cleaning and preparing the surface for optimal adhesion. - Removing any existing corrosion, dirt, or debris.

2. Coating Application - Applying the coating evenly. - Ensuring all internal surfaces are covered.

3. Curing - Allowing the coating to cure properly for maximum durability. - Monitoring the curing process.

4. Quality Control - Conducting inspections to ensure the coating meets specifications. - Addressing any issues immediately.

Conclusion

Internal coatings are essential for maintaining the efficiency and longevity of gas-cleaning plants. Kirloskar Corrocoat Private Limited offers custom solutions that provide exceptional protection against corrosion, erosion, and high temperatures. By investing in our internal coatings, you can ensure the continuous operation of your gas cleaning plant, reduce maintenance costs, and extend the lifespan of your equipment.

At Kirloskar Corrocoat, we are committed to delivering high-quality products and services to meet your needs. Contact us today to learn more about how our GCP - Gas Cleaning Plant internal Coating solutions can benefit your operations. Let us help you protect your valuable assets and achieve optimal performance in your gas cleaning plant.

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Innovative Structure Coating for Sustained Corrosion Defense- Kirloskar Corrocoat Private Limited

Kirloskar Corrocoat Private Limited's extensive engineering expertise and innovative techniques have been widely used in a variety of projects, offering corrosion protection for new structural steelwork as well as complete bridge refurbishment schemes. These projects integrate both coating and engineering skills to ensure long-term durability. Typical Projects Include: - Solutions to CUI (Corrosion Under Insulation): Handling the challenges of corrosion under insulation to extend the lifespan of insulated systems. - Protection Against SRB and Bacterial Attack: Safeguarding structures from sulfate-reducing bacteria and other microbial threats. - Accelerated Low Water Corrosion Solutions: Protecting structures subjected to low water corrosion, including piling. - Structural Steelwork: Enhancing the durability of structural steel through advanced coating solutions. - Tank Externals: Coating tank externals to protect against harsh environmental conditions. - Pipe and Pipe Support Externals: Ensuring the longevity of pipes and their supports with robust external coatings. - Pipe Riser Externals: Protecting pipe risers from external corrosive elements. - Support Steelwork: Strengthening support steelwork with high-performance coatings. - Flotation Units: Coating flotation units to withstand aggressive environments. - Stairways in Aggressive Atmospheric Conditions: Protecting stairways exposed to harsh atmospheric conditions. - Footbridges (Handrails and Support Structures): Coating footbridges to ensure safety and longevity. - Railway Bridges: Providing corrosion protection for railway bridge components. - Pipe Bridge Refurbishment: Refurbishing riveted open lattice and ‘N’ girder construction pipe bridges. - Bridge Refurbishment: Protecting and refurbishing bridges with cast/wrought iron and trussed girder configurations. Kirloskar Corrocoat Private Limited bridges refurbishment expertise extends to mechanical repairs, including bearing refurbishment, secondary scaffolding, and containment for work in environmentally sensitive areas. We also utilize polymer concrete materials and casting techniques to recreate intricate architectural details, ensuring both structural integrity and aesthetic preservation.

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Protective Pipeline Coating Solutions for Enhanced Durability- Kirloskar Corrocoat Private Limited

Pipeline Internal & External Coating is essential for the efficient functioning of any industry. Just like veins and arteries are crucial for the human body, pipelines serve as the lifelines of plants, ensuring smooth operations and optimum efficiency. However, similar to how cholesterol affects the body's vascular system, corrosion poses a threat to industrial pipelines. At Kirloskar Corrocoat Private Limited (KCPL), we specialize in providing high-performance epoxy glass flake, vinyl ester glass flake, and Polyester glass flake coatings to combat corrosion issues effectively.

Corrosion in pipelines can occur due to various factors, including the properties of the fluids flowing through them and the presence of impurities. It's a natural phenomenon, and over time, all bare pipes or metal surfaces are susceptible to corrosion. With years of experience, KCPL has successfully protected hundreds of kilometers of pipelines, both large and small bore, using materials specifically developed for internal and external pipe applications, even in the most challenging conditions.

Our coatings and linings find application across numerous sectors, safeguarding pipelines transporting materials such as oil, gas, seawater, industrial effluent, and potable water, among others. Offering advanced chemical and temperature resistance (up to 150°C immersed/240°C non-immersed), our coating technology ensures robust performance and mechanical strength, coupled with extremely low solvent emissions.

KCPL employs a variety of specialized application techniques, ranging from pipe spinning methods to advanced down-pipe blasting and coating equipment. This enables us to deliver high-quality finishes with swift turnaround times and reduced downtime. As a result, enhanced pipe coating solutions are now achievable using the full range of materials within our coating portfolio, ensuring the longevity and reliability of industrial pipelines across diverse service environments.

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Combating Marine Corrosion

Combating Marine Corrosion

A distinguishing feature of the marine environment is the universally present high salt content in the air and seawater which acts as a catalyst for the corrosion of offshore structures, such as offshore oil rigs, Intake Pump Houses in Thermal Power Plants Handling Sea Water. Corrosion damage in these environments is also influenced by the presence of other chemicals and various pollutants in the seawater, air and ports and many other areas. The corrosive forces inherent in marine environments pose significant threats to the integrity and longevity of metal structures. In this technical blog, we explore the complexities of corrosion, its detrimental effects, and the imperative role of corrosion protection strategies using Kirloskar Corrocoat in safeguarding marine assets.

Understanding Corrosion:

corrosion refers to the natural process of deterioration that occurs when metallic structures, components, or equipment are exposed to the harsh conditions prevalent in marine environments. This deterioration is primarily driven by electrochemical reactions between the metal and its surroundings, which typically consist of high levels of salt, moisture, and other corrosive agents present in seawater and marine atmospheres.

The Significance of Corrosion Protection in the Marine Industry:

The harsh conditions prevalent in marine environments make ships and metallic infrastructure susceptible to corrosion. Left unchecked, corrosion can compromise the structural integrity of vessels and structures, posing safety hazards and necessitating costly repairs. Mild steel, commonly used in marine construction for its affordability and strength, is particularly prone to corrosion, making corrosion protection imperative for the longevity of marine assets.

Protective Measures:

Manufacturers and operators within the industry take various precautions to protect their assets such as vessels and offshore structures from corroding. We will explore some of the standard methods utilised to protect metallic structures in the marine environment.

1) Design

Ship and infrastructure designers and operators make an effort to reduce corrosion and keep them secure, which aids in extending the lifespan of the structure or vessel. A few design features can assist in reducing the rate of corrosion and in turn reducing the required maintenance costs, including:

The placement of drains aids in the draining of water from decks, wells and low-lying areas. This eliminates a direct cause of corrosive activity.

In an effort to reduce galvanic corrosion, insulation is set up in areas where different metals are placed close to one another. Impressed current systems that monitor corrosive cell activity and apply currents to protective anodes can be installed to detect and manage corrosion.

Insulation is required in locations where temperature shifts, stopping thermal fatigue.

However, Design changes alone are often unreliable in fully protecting marine equipment from corrosion. While they may address specific vulnerabilities, they may not comprehensively account for the dynamic and multifaceted nature of marine environments. Maintenance challenges, cost considerations, and long-term effectiveness further contribute to their limitations. A holistic approach, combining design improvements with other corrosion mitigation strategies such as Glass flake Coatings and rigorous Maintenance, is essential for effective corrosion management in the marine industry.

2) Glass flake Coatings

Glass flake coating is widely regarded as the optimal solution for corrosion prevention in the marine industry due to its following outstanding properties.

Exceptional Barrier Protection:

Glass flake coatings are highly regarded for their ability to create a dense barrier, effectively shielding metal surfaces from corrosive elements such as saltwater and moisture.

Mechanical Strength:

These coatings exhibit exceptional mechanical strength, providing robust protection against abrasion, impact, and wear in the harsh marine environment.

Chemical Resistance:

Glass flake coatings demonstrate high resistance to a wide range of chemicals commonly found in marine environments, ensuring long-term durability. They effectively cover a wide pH range, from 1 to 14, making them suitable for various applications.

Strong Adhesion Properties:

With strong adhesion to metal substrates, glass flake coatings ensure the longevity and integrity of the coating system, even in challenging conditions.

Cost-effective Solution:

Glass flake coatings offer long-lasting corrosion protection with minimal maintenance requirements, providing a cost-effective solution for preserving marine assets.

Flexibility and Versatility:

Their flexibility allows for seamless coverage of complex marine equipment and structures, making them suitable for various applications.

A specially designed non-toxic, anti-fouling coating, called “Corrocoat Biofoul” forms a durable barrier that inhibits the attachment and growth of algae, barnacles, and other fouling organisms. By minimizing biofouling, this innovative coating helps maintain the efficiency and performance of marine equipment and structures, extending the service life of assets. 

Kirloskar Corrocoat and Corrosion Management:

Kirloskar Corrocoat has developed product lines that ensure they offer superior corrosion resistance for equipment and infrastructure surfaces exposed to harsh marine environments. With the right protective coating, seawater is not aggressive – our coatings withstand long-term exposure to high levels of salt for extended periods.

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Pipeline Coating Technology

Pipeline Coating Technology

Pipelines are the lifelines of various industries, transporting essential resources across vast distances. From oil and gas to water and chemicals, these vital arteries ensure the smooth operation of our modern world. However, the constant flow of fluids and exposure to harsh environments can take their toll on pipelines. Corrosion, abrasion, and erosion are major threats that can lead to costly repairs, downtime, and even safety hazards.

With decades of experience protecting hundreds of kilometres of pipelines each year, Kirloskar Corrocoat Private Limited, along with technology partner Corrocoat Ltd., has developed specialized coating techniques for pipeline internal coating starting from pipe diameters of 3 inches and onwards and external surfaces with no limitation. Kirloskar Corrocoat Private Limited (KCPL) offers effective solution with polyester, epoxy and vinyl ester glass flake coating for pipeline internal & external coating, even in the most challenging environments, ensuring their longevity and optimal performance.

Kirloskar Corrocoat has developed pipeline internal coatings that can withstand service conditions in sea water, DM water, raw water, and many other corrosive fluids. Expceted Life of our pipeline coatings in sea water service environment is more than 30 years.

What is Glass Flake Coating?

Glass flake coating is a high-performance coating system that utilizes specially crafted glass flakes embedded in a resin matrix. Imagine a maze of overlapping glass flakes, this is the structure of glass flake coating, a technology that shields pipelines from the ravages of time and environment. By forcing moisture and other detrimental substances to take a tortuous path, the coating drastically slows down their permeation, ensuring the long-term health and performance of these vital arteries.

Why Choose Glass Flake Coating for Your Pipelines?

Reduced Permeation:

The glass flakes act as a barrier, minimizing the penetration of moisture vapor through the coating, further enhancing corrosion resistance.

Superior Corrosion Resistance:

Glass flake coatings offer exceptional resistance to a wide range of chemicals, including acids, alkalis, and solvents, protecting pipelines from the corrosive effects of transported fluids and harsh environments.

Enhanced Abrasion and Erosion Resistance:

The overlapping flakes create a smooth, low-friction surface that resists wear and tear from the transported fluids, especially beneficial for pipelines carrying abrasive materials like slurries and sand.

Advanced Chemical and Temperature Resistance:

KCPL make Glass Flake Coatings Withstand temperatures up to 150°C (immersed) and 260°C (non-immersed), offering exceptional protection in harsh environments.

Mechanical Strength and Robust Performance:

Glass flake Coating ensure long-lasting durability and optimal performance under demanding conditions. Also, it requires minimal maintenance, saving valuable time and resources.

Long Life of Coating:

Compared to conventional coating systems, our glass flake coatings offer significantly longer life, reducing maintenance costs and downtime. As per our experience, the expected service life of Pipeline internal coating in sea water condition can be more than 30 years.

Improved Flow Efficiency:

The smooth surface reduces friction, leading to improved flow rates and reduced energy consumption.

Enhanced Safety:

Pipeline internal coating and Pipeline external coating gives protection from corrosion and other damage, glass flake coatings contribute to a safer working environment.

Cost-Effective:

Although the initial cost of glass flake coating may be higher than conventional coatings, the long-term benefits in terms of reduced maintenance and extended lifespan significantly outweigh the initial investment.

Conclusion:

Pipeline Internal Coating is scientific art to be performed with expert Technology and Technical Know How, this innovative solution can help you save money, improve efficiency, and ensure the safety and reliability of your pipeline system. Invest in the advanced protection of Kirloskar Corrocoat's internal glass flake coating solutions. Do not let corrosion and other threats compromise the integrity and performance of your pipelines.

Contact Kirloskar Corrocoat today to discuss your specific needs and explore how their coatings can help you achieve optimal pipeline performance and longevity.

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Antifouling Coating

Antifouling Coating

Introduction:

In maritime industries, combating fouling of submerged structures, pipes, and equipment is a persistent challenge. Fouling, the undesirable accumulation of materials on surfaces, significantly impairs efficiency and functionality. Whether originating from biological or non-biological sources, fouling poses a serious problem. The Kirloskar Corrocoat's Biofoul is an advanced anti-foul coating designed to combat the detrimental effects of biofouling in both sea water and freshwater environments.

The Historical Solution:

Centuries ago, mariners utilized copper sheeting to protect their wooden vessels from fouling. The copper-rich surface effectively deterred fouling agents. Bio foul employs a similar mechanism, presenting a copper-rich surface that deters fouling agents.

Unparalleled Durability and Resistance:

Unlike conventional anti-foul materials, Biofoul forms a robust and durable surface that withstands scuffing and high-velocity water flow. This makes it an excellent choice for static constructions, as well as pipework and other areas with varying flow velocities. Notably, it is highly effective in sea water intakes, where marine growth can significantly reduce inlet size, leading to reduced flow and increased maintenance costs. Additionally, marine piling, support structures, vessel hulls, and pontoons benefit from the long-term protection provided by Biofoul.

We had made one sample of Inlet screen where one half was coated with normal coating, while the other half was coated with a veil of Biofoul. After a span of 2 months, it was observed that the Biofoul-protected half displayed no indications of marine growth. Remarkably, even after 19 months, the Biofoul coating continued to effectively inhibit marine growth on the samples. This long-term success in restricting marine growth demonstrates the durability and effectiveness of the Biofoul coating.

Application Process and Compatibility:

Biofoul is a three-pack synthetic, hydrolysable polyester solution designed for application over a corrosion barrier coating, typically Kirloskar Corrocoat's own Polyglass materials. Its application is straightforward, facilitated by airless spray equipment, and it exhibits rapid drying and curing characteristics. This ensures a seamless and efficient application process, minimizing downtime.

Environmentally Responsible Solution:

One of the key advantages of Biofoul is its environmentally responsible composition. Unlike traditional chemical-based anti-fouling methods that often rely on chlorine, Biofoul contains no chemical agents. Instead, it leverages a unique blend of metallic copper pigmentation and flakes, rendering it non-toxic. This innovative approach addresses concerns about environmental impact and aligns with modern sustainability practices.

Conclusion:

Kirloskar Corrocoat's Biofoul represents a ground-breaking solution to combat the persistent issue of fouling in maritime industries. Its copper-rich composition, coupled with exceptional durability and resistance, provides unmatched protection for submerged structures, pipes, and equipment. Moreover, its environmentally responsible formulation makes it a forward-thinking choice for companies committed to sustainable practices.

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Pitting Corrosion

Pitting Corrosion

What is Pitting Corrosion?

“Pitting Corrosion” is the formation of holes in an otherwise relatively un-attacked surface. It is a form of localised corrosion that proceeds because of local cell action which produces cavities beginning at the surface. The cavities may or may not become filled with corrosion products. Corrosion products may form “caps” over the pit cavities which are described as “nodules” or “tubercules”. While the shapes of pits vary widely, they are usually rough saucer shaped, conical or hemispherical.

Pitting corrosion is quite common. It can occur on a metal surface because of localised differences in composition or surface contamination, deposition or incorporation of metallic and non-metallic particles, or contact with dissimilar metal. This type of attack can by caused by a break in a protective film on the metal surface, such as an inhibitor film, oxide film or break in coating. It also may be caused by the uneven deposition of solids (metallic salts) which in themselves create a local action because of the potential difference between the salts and metal surface. An example is ferric sulphate.

Where does Pitting Occur?

• Generally, pitting corrosion is a small anodic areas surrounded by a cathode

• The pitting phenomena are usually self-propagating, unpredictable and can lead to catastrophic failure.

• Pitting corrosion affects many metallic surfaces, but is prevalent on steels that rely on ‘passive films’ for protection.

• Pit diameter increases with time.

• On many stainless steels, higher concentration of chlorides can lead to a greater concentration of pits in a given area.

• Impurities of unwanted alloying components can great effect pitting rates.

Protective coatings for Pitting Corrosion

The Corrocoat Corrofill range consists of fillers for badly pitted steel, in application, which require a high performance, chemically resistant coating system.

One of our specialist corrosion protection coatings would then be applied to complete the process.

Corrocoat Corrofill

A two-pack organic peroxide, catalysed bis phenol ‘A’ polyester filler or grout.

Corrocoat Corrofill E

A general-purpose two or three pack epoxy filler, grout and repair compound.

Corrocoat Corrofill VE

A two-pack, vinyl ester filler and grouting material containing abrasion resistant fillers.

Contact us to find out more on how we can repair and protect corrosion pitted steel and other pieces of equipment or machinery, suffering from other types of corrosion.

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Look at Our Anti-corrosion Technology

Look at Our Anti-corrosion Technology

Corrosion affects everybody in one way or another. Monuments, structures, and products are a small percentage of infrastructure affected by the damage of corrosion. If corroded objects are left untreated, noticeable effects can start being present within the human body including:

Harm to the digestive tract

Skin and eye irritation

Respiratory damage

If we look at pure monetary terms, the cost of corrosion is estimated at between 3% and 6% of gross domestic product, amounting to a worldwide figure of 1409 billion dollars. Corrosion protection saves not only time and money but avoids many other problems including adverse publicity following corrosion-related incidents and/or loss of production.

How Do Our Anti – Corrosion Coatings Work?

Our coatings use glass flake fillers which are impermeable to increase considerably the diffusion path through the coating. This produces a barrier layer slowing moisture diffusion and the corrosion potential to a near non-existent level.

The flakes of glass orientate themselves within the coating film to reduce the passage of moisture vapor. This effect is known as the tortuous path.

Uses For Corrosion Protection Coatings:

Steel Bridges, Piling, and Seawater Immersion

Kirloskar Corrocoat has pioneered the use of single coat glass flake coatings for structural steel bridges, piling, and seawater. The range of coatings include some available for high temperature service. Immersion of these materials offer excellent application properties, good edge coverage, rapid cure times, and long-term corrosion protection eliminating many of the problems associated with conventional multi-coat painting systems. Kirloskar Corrocoat coatings are also used to provide long-term protection for structural steel, piling, oil rigs, jetties, bridges, and many other structures.

Corrosion Prevention Solutions:

With a highly skilled workforce, Kirloskar Corrocoat is available to carry out coating work on various materials at the highest possible quality. Successfully achieving corrosion preventative solutions, Kirloskar Corrocoat services a wide range of industries including:

The power industry

Petrochemical

Oil and gas

Marine

Water

Steel

Sugar

Benefits:

The cost of both money and time is a fundamental reason why the use of Kirloskar Corrocoat materials on structural steel is vital. By utilising Kirloskar Corrocoat’s glass flake coating, replacement of corroded materials become almost non-existent saving you from loss of production and possible incidents occurring. The improvements in glass flake quality, pioneered by Kirloskar Corrocoat, have allowed for the production of the zip code range of single coat structural steel coatings as a replacement for multiple coat materials.

Kirloskar Corrocoat’s dedicated technical managers and highly experienced estimators can help with even the most difficult of problems and provide a total solution from initial design consultation through to manufacture and installation.

Anti – Corrosion Technology At Work:

Kirloskar Corrocoat’s high performance materials have a proven track record of protecting process vessels, transport containers, road tankers, storage tanks, and underground storage tanks.

The linings produced have often been used to provide long-term protection for pipelines, preventing the need for expensive metallurgical solutions. We recommend polyglass/corroglass/armagel as the most effective corrosion preventative system for internal lining of pipes. With our engineering expertise, development of high-quality pipe blasting and pipe coating equipment is accessible.

Conclusion:

Kirloskar Corrocoat Pvt. Ltd. has the ability to provide extensive end-to-end solutions by utilising the knowledge and experience of our expert teams. Making sure your materials are protected against corrosion, abrasion, and erosion will not only prolong the life of infrastructures but ensures the health of everyone is maintained. With extensive consequences, not using protective coating solutions become increasingly expected.

Through years of relationship building and thousands of successful projects undertaken some still working well after 30 years of service, Kirloskar Corrocoat Pvt. Ltd. has earned its place in the market as a company that can be trusted to carry out work right first time every time.

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Coating Application Techniques

Applying Coating Correctly:

Successful application of protective coatings is pivotal to ensuring infrastructures receiving coatings withstand potential corrosion. There are several detrimental factors to consider if the coating is applied incorrectly and corrosion does occur. Some factors may include:

Bodily harm including irritation and respiratory damage

Loss of production with machinery being inoperable

Financial strain with replacements or repairs

Adverse incidents in public locations

Loss in revenue with downtime

Spray Techniques:

Hand- Striping

An important first step when applying a coating correctly is hand-striping. Before the first general coat is applied it is recommended to complete an extra spray pass or stripe coat. This coats all edges, corners, joints, and other irregular surfaces to ensure all surfaces are ready for the first coat and an adequate film can develop.

Cross-layer application

Applicators often spray coatings with a horizontal pass first which unfortunately can lead to a series of issues that may have a detrimental effect on the coating’s performance and service life. By beginning with a horizontal application, a dry edge can eventuate in the bottom of the spray pattern and from there gravity will drag the liquid film causing an over thickness which can sag and run. To avoid this, it is essential the vertical passes of the spray gun are used first followed by horizontal passes, creating a cross-layer application.

Why is it important to apply a vertical pass first?

Beginning with a vertical pass avoids a defined edge which a horizontal pass can cause. Increasing the stability of the coating, vertical application technique also aids in the uniform thickness of the applied film across a large area.

To maximise mechanical adhesion and encourage optimum surface coverage, the distance of the spray gun to the surface is extended to approximately 24 to 36 inches to avoid an orange peel appearance and give more even coverage.

Corners and Edges

Another critical aspect of spraying technique is the correct approach to spraying corners and edges. When coating a corner or edge, particularly one with a small radius, the natural phenomenon of the paint is to retract due to surface tension this can be exacerbated by incorrect application techniques. If the applicator simply sprays each face and does not treat the corner, the edge will not be protected, and corrosion will occur more rapidly.

Atomisation

Paints and coatings must be atomised satisfactorily to facilitate homogeneous and uniform coverage. When atomisation is not correct, the materials ability to coalesce will be compromised and the coating may have a textured finish similar to that of orange peel. This effect may have an impact on the coatings performance in its intended service.

Thickness testing

Ensuring the thickness of the anti-corrosion coating has been correctly applied is vital to the success or failure of the product. Corrocoat offers inspection services to ensure quality assurance and standards have been met. We perform a thickness test using a coating thickness gauge.

Conclusion:

The application of protective coatings can greatly affect whether infrastructures are protected against corrosion. Correct techniques are a simple solution to ensuring the successful outcome of anti-corrosion coatings. At Kirloskar Corrocoat, all our products are applied within stringent standards, and everything we coat with our Kirloskar Corrocoat product range is returned with a quality assurance certificate.