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Ceramic Polymer: Restoration of ensilage tank with Proguard CN-1M – effective protection against chemical influences and abrasion

03-14-2016 02:52 PM CET | Industry, Real Estate & Construction

Press release from: Ceramic Polymer GmbH

Above: Washed-out-concrete-effect?  - caused by aggressive acids in the ensilage. Below: Coated wall area

Above: Washed-out-concrete-effect? - caused by aggressive acids in the ensilage. Below: Coated wall area

Heidelberg/Germany: The ensilage tank of a huge biogas plant showed extremely heavy concrete erosions due to high chemical attack from the fermentation material. The concrete substrate had to be refurbished urgently to ensure the functionality of the tank and prevent disastrous leakages. Henceforth, the product PROGUARD CN-1M protects the concrete reliably against chemical attack.

It is a fact; uncoated concrete does not suffice for long-term operation against chemical attack! Through the microbiological decomposition process and the acidic environmental conditions ensilage, biogas and biomass cause an extreme chemical load for the concrete substrate. A high performance coating is required to protect against serious concrete damage.

The ensilage tank showed advanced concrete erosions down to the steel reinforcement, induced by biogenic sulfuric acid attack (BSA). Thus, the steel was exposed to high corrosion risk; immediate action was required.

Technical details

Project: Refurbishment of a concrete tank for biogas ensilage
Size of the tank: Height of 5 m, diameter of 4.5 m
Storage medium: Renewable raw materials, manure, slurry with a pH-value of 4-5
Coating product: PROGUARD CN-1M
Application of the coating: K. H. Strohbeck GmbH & Co. KG, Kernen-Stetten/Germany

Firstly, the surface was grit blasted to remove loose concrete. Then the tank could be restored with conventional concrete grout.

Afterwards the walls were undercoated with the concrete-primer CP-SYNTHOFLOOR BETA 8016 and lightly sprinkled with quartz sand to achieve an anchorage profile for the protective coating.

The application of the high-grade chemically resistant coating PROGUARD CN-1M was conducted by airless spraying in a single layer with a thickness of 600 µm. One application procedure is enough to accomplish a reliable protection against aggressive chemical attacks and abrasion damages.

The further process within this extensive restoration was the floor treatment. The repaired concrete was also primed and sprinkled with quartz sand. In this area the product PROGUARD CN-1M was easily applied with a rubber squeegee.

The Ceramic Polymer GmbH produces high-quality, solvent-free protective coatings for different kinds of industries. Due to the integration of microscopic ceramic and other special particles, coating systems with outstanding physical properties such as excellent chemical resistances, high temperature stabilities and extreme abrasion resistances are generated.
The Ceramic Polymer coatings are applied directly on the blasted substrate (e.g. steel, stainless steel, concrete) without the previous use of a primer. In this way extreme adhesion is achieved.
The scopes of the Ceramic Polymer coatings are for instance all kinds of storage tanks, pipelines or process vessels for the oil & gas industry as well as different maritime constructions, waste water or drinking water applications.

Ceramic Polymer GmbH
Stephanie Wuensch
Daimlerring 9
DE-32289 Roedinghausen / Germany
+49 (0)5223-96276-0

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