Repair & Rebuild of Acid Neutralization Trench Lines in Power Plant

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Problem:

Acid resistant tiles that were installed along the neutralization trench lines of a Thermal Power Plant had completely worn out within a span of 12 months. This as a result had caused severe corrosion across the civil & concrete areas of the DM plant, forcing the plant maintenance teams to replace and repair the acidresistant tiles frequently.

The drastic increase in downtime & maintenance costs required the plant to adopt a more bulletproof protective flooring system that would help overcome the damages incurred and ensure the smooth operation of the DM Plant.


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  Solution:

On inspecting the damages and assessing the problems, Arudra reckoned to redo the entire civil works using a 100% solid, 3-part epoxy grout (Duromar DuroFil) along with a top layer of the acid-resistant epoxy liner (Duromar DF – 4301).
The existing tiles were removed throughout the trench and the severely damaged portions were rebuilt with Reinforced Cement Concrete (RCC).


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The concrete surface was then thoroughly prepared to ensure a clean and rough finish was achieved and Duromar DF – 1301 concrete sealant was applied to ensure all the concrete pinholes/seepages were sealed. Duromar DuroFil, a specially formulated 100% solid epoxy grout used in rebuilding severely chemically attacked concrete floors and secondary containment areas were then built up to a thickness of 6mm – 7mm throughout the trench lines.

The DuroFil was left to cure for 24 hours and a 1mm – 1.5mm lining of Duromar DF – 4301 was applied on top of the DuroFil. Duromar DF – 4301 is a 100% solids (zero VOC) Novolac floor coating with outstanding chemical resistance to acids, bases, and solvents, primarily used in floors and secondary containment areas subject to chemical exposure.

Result:

Installation of DuroFil followed by Duromar DF – 4301 successfully helped provide a solid foundation and outstanding acid/chemical resistance for the neutralization trench, covering a surface area of approximately 50 m².

This expert 100% Solid (Zero VOC) Epoxy grout & rebuild solution not only helped solve a range of operational & maintenance issues but also greatly helped in enhancing the Asset Life of these concrete areas exposed to aggressive chemical environments.

Arudra successfully executed this challenging installation within a span of 7 days, providing the end-user with risk-free operations for years to come.

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