How does cooling tower corrosion occur and what are the effects?

How does cooling tower corrosion occur and what are the effects?

Over the past decades, metal cooling towers have become popular. Tower corrosion may occur in as little as 7 years depending upon water treatment and environmental conditions. Severe rusting to the point of distressed metal of the tower basin and support structure results. Corrosion causes water leaks and increases water consumption. Structural integrity of the tower itself is reduced and gradually performance deteriorates.

Inevitably, corrosion makes it necessary to replace the equipment prematurely, often at a cost of tens of thousands of dollars and more.

How can Pancrete be of help?

Pancrete provides a tough, corrosion-resistant coating that is applied directly to the interior cooling tower metal surfaces. This restores the surfaces so they are strong, smooth and easy to clean.

What about structural integrity? My sump on the tower is practically rusted through?

The normal application thickness of Pancrete is ¼ inch. This thickness helps to distribute stress across greater surface areas. After Pancrete is properly applied, maintenance personnel can walk across the basin without fear of falling through the corroded metal which may be a problem before the tower has been restored. Greater thicknesses of Pancrete can be applied as well.

Is this product resistant to water treatment chemicals?

Yes. Pancrete was engineered in our laboratories to resist commonly used corrosive chemicals.

Can I be certain the product will work on my tower?

Pancrete will work on galvanized towers.

Is there any special equipment needed to apply Pancrete?

No special equipment is needed for application.

What’s involved in surface preparation?

There are instructions provided. The most important thing is removing old rust, deposits and oils from the metal surfaces. This may be done by abrasion blasting using a soft abrasive such as sodium bicarbonate, walnut shells, etc. A wire brush may also be used.

How long will this procedure take?

Surface preparation is the most time-consuming step. The tower is drained and residual dirt or debris is removed by brushing and hosing down the surfaces. Total tower coating process can be completed in less than a day.