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Oil Cooler Water Boxes


Oil Cooler Water Boxes


Power Generation,



Aug 2010,



Cast Iron,



Epo-chem™ RS 500P,

Epo-chem™ RA 500M,



60°C Salt Water Immersed,



To refurbish and extend the operating life of extensively corroded, 35 year old, oil cooler water box.

Deep pitting was found in many areas requiring pit filling and reinforcement using composites. Water boxes needed to be coated on site with minimal disruption to adjacent turbine hall.

Prepare, coat, cure and complete in a duration of four days.


PGEN 6 photo 2 PGEN 6 photo 3 PGEN 6 photo4


35 y.o. cover        Covers after 1st coat     Boxes: blasted, primed & coated


Chemco’s Solution:

We recommended coating with RA 532, a solvent-free epoxy glass-flake filled coating, which has excellent resistance to this particular environment.



Water Boxes – Onsite:

  • Needle gun difficult to access areas
  • Remove graphitised materials with high pressure water blast at 20,000psi
  • Assess damage and apply one coat of RS 500P integrated with a fibreglass matting to cope with low pressure
  • Application of two coats of RA 532

Covers – Workshop:

  • Abrasive blast to AS1627.4 Sa2.5 with a nominal surface profile of 75µm.
  • Hot wash to reduce presence of metallic salts to <25ppm and re-abrasive blast.
  • Application of RB 332



The first unit was coated in 2006 with an expected operating life of two years due to plant redundancy. This unit has continued to remain online and in great condition for a substrate that is more than 60 years old. It is expected to last another ten years.

The newly coated water boxes were completed without incurring costs for abrasive blasting, encapsulation and were carried out with reduced downtime.


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