At CSC Services, we believe every layer of coating protects more than surfaces, it safeguards operations, compliance and confidence. When our water industry client discovered outdated coatings within their internal pipework, we acted swiftly. We combined technical expertise with clear communication, ultimately delivering durable, compliant industrial coatings that support their infrastructure’s integrity and performance.
Upon inspection, we found the existing coatings failed to meet DWI-approved specifications, leaving both materials and structures vulnerable. Additionally, corrosion had taken hold in multiple areas of the pipework, raising concerns about safety and reliability. Acting fast, we outlined a plan that corrected specification issues, removed corrosion and effectively upgraded the coating system.
The project faced several hurdles. First, the pipework ran through narrow access routes, limiting the scope for equipment and setup. Next, the job required controlled environmental conditions to manage temperature and humidity during removal and re-coating phases. Finally, we had to align with stringent quality standards and documentation requirements – from method statements to permits, all while upholding operational continuity.
We started by setting up our mobile welfare units at the restricted site entrance and running full inductions, briefing sessions and permit checks to ensure safety and clarity. Then, our operatives prepared the asset by emptying the sump, erecting scaffolding, drying the tank and creating a controlled environment for coating work.
Once conditioned, our NACE Level 2-certified team removed the old coatings using calibrated shot blasting, achieving the required SA 2½ cleanliness and a 75 µm surface profile under climate control. With the surface prepared, we deployed a high-performance industrial coating, BASF Masterseal M808, a DWI-approved polyurethane, applying it in three coats: a stripe coat around the flanges and fixtures, then two controlled builds between 150-300 µm per layer. We monitored temperature, humidity and thickness throughout, and captured time-stamped photographic records for quality assurance.
Finally, we conducted a spark test and final inspection, producing a full QA package that detailed calibration records, curing data, batch numbers and environmental logs. After seven days of curing at 20 °C, we cleaned the tank and handed it back fully operational and coated to spec.
Because we replaced substandard coatings with an approved, high-performance system and documented every stage meticulously, the client now benefits from a robust, corrosion-resistant internal pipework network. This precise industrial coatings solution gives them long-term peace of mind, regulatory compliance and infrastructure resilience that lasts.
If your facility needs expert industrial coatings, whether in pipework, tanks, bunds or confined environments, CSC Services can deliver solutions that combine durability, documentation and minimal disruption. Contact us today to discuss your project.