A process vessel experienced a brick and mortar lining failure resulting in the process environment consuming the carbon steel shell 90’ above grade. A full repair would have required more than a week of unscheduled downtime, so an RFQ was sent out to contractors for an external patch that wouldn’t further degrade the internal liner. Other proposals called for welding, risking further liner damage that could cause bricks to enter the process.

Corrocoat proposed applying a composite patch
designed to withstand the corrosive 180 F environment that required no hot work along with less time and investment than all other proposals.

The area was first scrapped carefully by hand to expose the level of degradation, exposing a 5’ vertical void in the shell surrounded by smaller voids. The thinner areas near voids were prepared with power tools (SSPC-SP3) to protect the integrity of the liner prior to commercial blasting the surrounding areas (SSPC-SP7).

Once clean of excess corrosion, the surfaces were
washed to remove salts prior to final surface preparation to white metal (SSPC-SP11 and SSPC-SP5) and priming with Corroglass 600 Series.