The condensate tank base had lost its integrity, corrosion has damaged the floor due to water forming under the condensate, and being in direct contact with the steel, once the epoxy paint lining was damaged.
Application took place in 4 steps:
1. Corroded steel tank base and 1st course shell were grit blasted to SA 2.5 cleanliness and to a minimum 75μm profile.
2. A Zink Primer was spray applied to the blasted area.
3. Polyurea QuickSpray layer of 2.5mm was applied with Graco XP-2 high pressure spray units.
4. All inlet high abrasion areas were sprayed with a layer of 5mm to provide extra protection.

Failure to attend to the corrosion problem would have caused the tank to condemn. To offer a similar rigid epoxy as previously applied meant this would cracked due to movement of the tank base causing premature failure again.
VIP Polyurea was specified as a long term protection system with flexibility.
The complete process of surface-preparation and application of base coat was successfully completed in 10 days despite extreme HS regulations and conditions of spraying internally.