Cooling Tower Restoration Photo Albums
Marley NC8302 San Marcos TX 2023
Quincy MI Condenser Lining Project 2022
Evapco AT-185 Tower Restoration 2021
Evapco AT-19-311 - Bossier City LA - March 2018
Marley Restoration Dallas TX 2021
Evapco AT 8 - 712B 2022
Evapco AT 12-624B Woodbridge NJ 2022
Evapco AT 29-121 Restoration 2022
Evapco AT 19-58 Pittsburg Kansas 2018
Evapco AT 14-99 New York City 2018
Southeastern Industrial Linings is a small, family-run company. We work with national corporate clients who manage hundreds of cooling towers, and we have been restoring these towers for more than ten years. Our clients wouldn’t keep having us restore 6-8 towers each year for a decade if we weren’t doing quality work. We also provide restoration services for small businesses, churches, and anyone interested in repairing an existing tower rather than purchasing a new one. If you’re unsure about how to handle your tower, contact David Puckett at 404 626-4771 to discuss your situation.
Unlike most cooling tower restoration companies that rely on grinders and canned coatings, we take a different approach. We have invested in two complete sets of specialized application equipment to manage a variety of projects. One set is designed for towers accessible from ground level, allowing us to work efficiently and keep costs low. The other set is built for high-rise buildings, enabling us to transport equipment to rooftops and apply linings safely and effectively at height. Thanks to this advanced technology, we provide a superior finish and longer-lasting protection on every restoration job.
Once the tower’s sheet metal has been repaired and Sponge Blasted, the surface is acid‑etched and primed to ensure maximum adhesion. We then spray‑apply PPG’s SPI PolyShield HT™ 100F, a high‑performance, 100% solids, zero‑VOC pure polyurea elastomer engineered for fast‑setting, durable, and flexible protection. The material is applied at 165°F and 3,000 psi, achieving a minimum average thickness of 60 mils . The coating cures almost instantly—it can be walked on within 10–12 seconds .
For comparison, most brush‑ or roller‑applied coatings typically achieve only 6–8 mils, especially on vertical surfaces, leaving far less long‑term protection
People ask, "What makes Polyurea so special?"
Polyurea stands out from other materials (like epoxy or polyurethane) because of its extreme physical properties:
Lightning-Fast Cure Time: While epoxy can take 24 hours to dry, polyurea is applied at 165F and can be walked on within seconds.
Insane Durability: It is highly resistant to abrasion, impact, and corrosion.
It doesn't crack easily because it’s flexible—it can stretch up to 300% or more without breaking. Weather-Proof Application: Unlike most coatings, polyurea is relatively insensitive to moisture and temperature during application.
You can spray it on a surface that is 20F or 100F and it will still cure properly. Chemical Resistance: it stands up to harsh chemicals, oils, and fuels, making it a favorite for industrial containment.
Polyurea is often considered the "gold standard" for cooling tower linings because it solves the three biggest headaches of tower maintenance: leaks, chemical corrosion, and downtime.
Cooling towers are brutal environments—they are essentially giant, hot, vibrating humidifiers filled with chemicals.
1. Seamless Waterproofing
Unlike sheet liners (which have seams that can fail) or epoxy (which is brittle), polyurea is spray-applied as a monolithic (single-piece) membrane.
Bridge the Cracks: Because polyurea has high "elongation" (it can stretch up to 300% or more), it moves with the structure.
As the cooling tower vibrates or expands/contracts with temperature changes, the polyurea flexes instead of cracking. Leak-Proof: It seals every nook, cranny, and bolt head, creating a "tub" that is impossible for water to penetrate.
2. Chemical & Corrosion Resistance
Cooling tower water is treated with aggressive chemicals to prevent algae, scale, and bacterial growth (like Legionella).
Chemical Shield: Polyurea is highly resistant to the biocides, chlorine, and acids used in water treatment.
Corrosion Stop: It creates an airtight barrier that stops the "oxidation cycle," preventing steel towers from rusting and concrete basins from eroding.
3. Thermal Shock Resistance
Cooling towers experience "thermal shock"—rapid swings between hot process water and cold ambient air.
Most coatings become brittle and flake off when the temperature drops, but polyurea remains flexible from -30°C to over 120°C. It won't delaminate or "pop" off the surface during a sudden freeze or heat spike.
4. Minimal Downtime (The "Money" Factor)
This is usually the deciding factor for facility managers.
Return to Service: A cooling tower is the heart of a building's HVAC or a plant's production. You can’t leave it off for a week while epoxy dries.
Speed: Polyurea can be sprayed and the work to reassemble the tower and install the fill media can start immediately instead of waiting days for epoxy to dry.
Bottom line is we can restore your cooling tower, regardless of its current condition.
Call 888 626-4771 to talk to David Puckett regarding your tower, or to receive a no-obligation, comprehensive, and guaranteed quote for a complete restoration, please send pictures of your cooling tower, along with the model number and address, to SILinings@gmail.com.
Since 2011, we have specialized in restoring cooling towers, allowing you to 
save 50% or more compared to the costs of replacement. Southeastern Industrial Linings (SILinings) focuses on high-quality cooling tower rehabilitation. Unlike general maintenance companies that simply patch leaks and make temporary repairs, SILinings adopts a comprehensive approach to restoration.
Our service is unique in the industry. We remove and discard the old fill media. Advanced materials and preparation techniques are used to ensure optimal results while significantly reducing costs compared to replacing an entire cooling tower. Our process includes repairing or replacing rusted-out sheet metal, Sponge Blasting (www.SpongeJet.com) the tower's interior. Sponge Blast media is an aluminum oxide-impregnated polyurethane sponge that aggressively removes rust and corrosion from metal surfaces. Acid etching and priming are then performed before applying a protective Polyurea lining. This approach enhances the tower's longevity and performance—benefits that a new tower may not provide.
If a contractor tells you he is going to grind the rust out of the tower, beware!
When it comes to cooling tower restoration, is grinding sufficient? The short answer is no. While grinding is a common "quick fix," it cannot match the surface quality, longevity, or structural integrity provided by sponge blasting.
Think of it this way: grinding is like using a coarse eraser to clean a deep stain on a piece of wood, while sponge blasting is more like a surgical deep-clean.
The Comparison: Grinding vs. Blasting With Aluminum Oxide
1. Surface Profile (The "Anchor")For a restoration coating (like Polyurea) to stick, the metal needs a specific "profile"—tiny microscopic peaks and valleys.
- Grinding: Tends to polish or "smear" the metal. This creates a smooth surface that coatings struggle to grip, leading to premature peeling or "delamination."
- Sponge Blasting With Aluminum Oxide: Aluminum oxide has a Mohs hardness of 9, making it one of the hardest materials available, second only to diamond. The sponge media contains aluminum oxide that strikes the metal surface, creating a consistent, jagged profile that allows the coating to mechanically lock into the metal.
2. Deep Pitting and Oxidation
Rust isn't just on the surface; it lives in microscopic pits.
Grinding: A flat grinding disk or wire wheel often skips over the bottom of deep pits, leaving "seed" rust behind. Once you paint over it, that trapped oxidation continues to eat away at the tower from the inside out.
Sponge Blasting: The sponge particles are compliant; they flatten upon impact, forcing the Aluminum Oxide abrasive into those tiny pits and craters to pull out every last bit of oxidation.
Comparison Table
| Feature | Power Grinding / Wire Wheel | Sponge Blasting (Sponge-Jet) |
| Surface Cleanliness | Leaves "smut" and deep-pit rust | Near-White or White Metal finish |
| Coating Adhesion | Poor (smooth surface) | Excellent (high anchor profile) |
| Environmental | High dust, high spark risk | Lower dust, low ricochet |
| Substrate Health | Risk of thinning the base metal | Non-destructive to healthy metal |
When is Grinding "Good Enough"?
Grinding is only "as good" if you are dealing with a very small, localized spot (less than a square foot) where bringing in a blast rig isn't cost-effective. However, for a full basin restoration or structural rails, grinding is often a "band-aid" that results in the rust returning within 12–24 months.
What about rusted-out sheet metal?
Any rusted-out sheet metal is repaired or replaced. We have drawings of most tower panels and pieces based on years of experience in tower
restorations. For pieces we don't have drawings for, we use advanced 3D modeling and Computer-Aided Design (CAD) software to create a drawing of the required panel or component, which is then fabricated at a local sheet-metal shop. This drawing is an example of a hot water deck and water distribution box we designed for a steel overlay of a wooden tower.
The Protective Coating
If the contractor says his "Protective Coating" is coming out of a 5-gallon pail, be very cautious.
Many products used to line cooling towers are two‑part polymers that take anywhere from 15 minutes to 2 hours to cure—and even longer in cold weather. Worse yet, some companies still use epoxy, which can take several days to cure when temperatures drop. The problem with these slow‑curing materials is that they tend to run down vertical walls before they harden, leaving behind a thin, uneven coating. Since most cooling tower restoration happens in winter, the cold only makes this issue worse. The end result is a weak, thin layer that provides very little long‑term protection.
Our Polyurea Lining System avoids these problems entirely. It cures quickly in both hot and cold conditions and creates a strong, durable finish. However, applying Polyurea correctly requires specialized, heavy‑duty equipment—something most restoration companies don’t invest in. Many rely on basic tools like grinders and wire brushes for surface prep, and they apply coatings with brushes and rollers from standard 5‑gallon buckets. Without advanced machinery, they simply can’t achieve the same quality or durability.
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Cooling Tower Restoration makes economic sense considering the cost of new towers. Brand new towers can 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 preventing rust from clogging your filters.
Southeastern Industrial Linings performs restorations nationwide. We have restored towers in downtown Chicago, New York, Miami, Los Angeles, and Las Vegas. Our clients include Walmart, Sears, JCPenney, Jones Lang LaSalle, and CBRE.