Cooling Tower Restoration Program

A Sprayed On Polyurea Lining System will permanently stop all leaks and protect the tower from future rust and corrosion. We can perform a cooling tower restoration regardless of the current condition of your tower.

We'll remove and discard the old media. Vapor blast the interior sheet metal surfaces to remove all rust and corrosion. Evaluate the conditon of the metal including the hot water decks. Components that have rusted away and are too bad to repair are replaced using locally fabricated parts. Polyurea is applied at an average of 60 mils and finally new modular fill media is installed.

Cooling Tower Restoration makes economic sense considering the cost of new towers. Brand new towers develop leaks as early as 5 years. They start rusting and corroding from day one. Polyurea will never rust or corrode making the tower easier to clean and not clogging your filters with rust.

Preparation:

Poor surface preparation is the number one reason that coatings fail. Our cooling tower restoration service starts with removing and discarding the old fill media. Then we Vapor Blast the interior of the tower to remove the rust and corrosion. Vapor Blasting is sandblasting with water and garnet but it reduces the dust by up to 90%. Garnet is a industrial gemstone that creates a profile virtually free of embedment. It is safe and non toxic with very low free silica levels (generally less than 1%). It is one of the most durable abrasive blast medias available anywhere in the world. It's sharp, angular shape is plenty aggressive enough for tough surface preparation like rusted cooling towers

Since Soluble salts are a major reason for coatings failure we remove them by adding chemicals to the blasting water. Grinding the rust out of the tower will not achieve surface prep comparable to vapor blasting. Grinding cannot reach into corners and unless the tower is pressure washed with a soluble salts remover the salts could cause a coatings failure.

Cooling Tower Case Repair:

We evaluate the condition of the cooling tower case after we finish blasting the tower. Small holes are repaired using polyrea. Polyurea has about 4,200 psi tensile strength and it gels so fast it can easily bridge holes as seen in this video. As you can see in the video the Polyurea gels in 9-10 seconds.

Panels that have large rusted out areas are replaced. The sheet metal parts needed to repair the tower are custom made by local fabrication shops. It is quicker, there's never a problem with obsolete parts. Watch the video below to see an example of the fabricated sheet metal parts installed in a tower.

Industrial Polyurea Cooling Tower Lining:

Before the newer generation spray on linings, like Polyurea,  paint brushes and rollers were used to apply cooling tower coatings. This caused them to be thin on the vertical surfaces and on the edges resulting in cooling tower leaks. We apply the Polyurea at about 60 mils thick.

Since it is a monolithic coating there are no seams or underwater terminations to fail. Polyurea is one of the most rugged industrial lining systems used today. It is a plural component lining that's applied at 165 degrees and 3,000 psi. It cures to touch in about 9-10 seconds, has no VOC's and it's flexible for life. At 60-80 mils thick it has around 4,250 lb tensile strength and it never cracks. The cooling tower is ready for service as soon as the media installation is complete. The tower will be much easier to keep clean with the Polyurea lining since it never rusts. It eliminates the problems of rust clogging filters and screens and of cooling tower leaks.

New modular fill media is installed thereby restoring the efficiency of the tower.

A complete cooling tower rehabilitation will add at least another 25 years life expectancy. We can rebuild any cooling tower or condenser regardless of its make, size or condition.

Southeastern Industrial Linings has restored towers in downtown Chicago, New York, Miami and all over the Eastern US. Our clients include WalMart, Sears, JCPenney, Jones Lang LaSalle and CBRE.

Polyurea Used In Cooling Tower Linings
HT100F Chemical Resistance Chart