Concrete and steel structures in wastewater treatment plants are constantly exposed to demanding environments. The process causes significant damage to metal and concrete substrates. Plant operators who want to work efficiently need protective coatings and corrosion protection tailored to their requirements. From Senn Beteiligungs GmbH (SENN Gruppe).
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Wastewater Treatment Efficiency and Plant Protection Through High-Performance Coatings

Written by SENN Gruppe on .

Concrete and steel structures in wastewater treatment plants are constantly exposed to demanding environments. The process causes significant damage to metal and concrete substrates. Plant operators who want to work efficiently need protective coatings and corrosion protection tailored to their requirements.

The equipment used in wastewater treatment plants, such as tanks, pipes, pumps, etc., is susceptible to various corrosion mechanisms due to the corrosive environment in which it operates. To achieve optimal long-term protection for water and wastewater treatment plants, the environmental conditions and specific operational requirements must be understood. It is important to identify what exactly leads to equipment failures and how these failures can be prevented. In this way, suitable long-term protection systems can be selected for all areas of the plant.

What are the specific requirements for corrosion protection in wastewater systems?

Suitable surface protection coatings can significantly extend the service life of components in wastewater systems. However, since the components and materials in such systems are exposed to enormous environmental stresses, selecting an appropriate coating for each part of the plant can be a challenge.

Common problems for metal and concrete surfaces in wastewater infrastructure:

  • Abrasion and erosion from coarse particles in flowing wastewater and sludge treatment
  • Chemical contamination due to the highly aggressive nature of the wastewater and the enriched chemicals used for disinfection and pH adjustment
  • Concrete corrosion and severe attacks on metal parts from biogenic corrosion (especially in covered wastewater systems)
  • Contamination risk and environmental hazard from leaks, cracks and joint failures
  • Mechanical abrasion from the weight and movement of mechanical equipment

Time for Effective Rehabilitation of Concrete Tanks and Metal Structures

After several years of operation, concrete structures in wastewater systems show severe damage due to chemical attacks and wastewater flow. The polluted atmosphere, weather, temperature fluctuations and solar radiation are additional factors – resulting in spalling, cracks and corrosion in the concrete. The steel reinforcement becomes exposed and corrodes, leading to concrete damage. Furthermore, the edges of clarifier basins must withstand high mechanical loads from the movement and weight of the bridge scraper.

Pumps, screws, agitators, grease and oil separators, screens and pipelines suffer erosion and corrosion damage after only a short period of operation if they are not adequately protected.

Efficient functionality is called into question, and in the worst case, failures occur that disrupt the entire treatment process. Regular maintenance and rehabilitation with suitable coatings is essential for the efficiency of this equipment.

Chesterton Delivers Long-Lasting High-Performance Coatings

Chesterton's ceramic and mineral-reinforced, wear-resistant epoxy coatings offer high chemical stability, abrasion resistance and corrosion/erosion resistance. They are therefore ideally suited for applications in water and wastewater systems.

The portfolio of protective coatings excels through its versatility. For all requirements, Chesterton offers effective corrosion protection systems that enable a significant extension of plant and equipment service life, thereby significantly increasing the efficiency of water and wastewater treatment plants.

Our high-end coatings offer:

  • High-grade resistance to abrasion, aggressive chemicals and acids – through the enrichment of ceramic and specialty particles
  • High adhesion strength to the substrate – undercutting corrosion and delamination are prevented
  • High edge protection – more than 70% coating thickness retention on sharp edges (minimal edge recession)
  • Exceptionally low permeability through solvent-free formulations
  • Smooth, low-friction surface – enables higher flow velocities, good release of solids and easy cleaning
  • Depending on the product, application by trowel, roller or airless spray
  • Single-coat application with fast curing times – allows rapid return to service

Let our corrosion protection experts advise you. Together we will find the best coating solution for your plant applications.

Trust Our Experience in the Wastewater Sector

Improving the efficiency and reliability of wastewater treatment plants with our products is part of our daily work. For many years, we have been helping industrial and municipal plant operators worldwide to increase their operational efficiency and protect their plants for the long term.

See our topic on the Chesterton Blog "Reliability Matters": How to Gain Pump Efficiency Through Restoration and Protective Coatings

Here is a brief insight into our many years of experience in the wastewater sector:

Case Study No. 1 – Aeration Tanks Rehabilitated and Protected with ARC CS2(E)

The aeration basins of a wastewater treatment plant built in the 1970s, which treated the waste of a major food manufacturer, needed to be renovated and protected.

Through the project, the customer saved 200,000 euros compared to the cost of new construction.

Case Study #2 – New Clarifier Lining Has Lasted Over 11 Years

This case study describes the successful rehabilitation of a clarifier basin with ARC S1HB – free of defects or failures after over 11 years of operation.

Case Study #3 – Rehabilitation of a Buffer Tank with Ceramic Polymer Concrete Coatings

A wastewater treatment plant in Germany has a massive equalization basin with a length of 70 m. Due to extreme concrete damage, the basin was extensively rehabilitated.

Conclusion

With its ARC and Ceramic Polymer coating systems, Chesterton offers high-quality industrial coating solutions for the demanding water and wastewater sector. We are happy to support you with our experience and expertise to find an ideal coating protection solution for your requirements.

With our high-performance coatings, you can achieve the following results:

Extended Plant Service Life
Protection against corrosion, erosion, wear and chemical attack significantly extends the service life of wastewater systems.

Reduced Maintenance Costs
Less corrosion damage and less wear means fewer repairs and equipment replacements.

Improved Operational Reliability
Protection against failures and malfunctions due to damage increases plant productivity.

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