At Specialist Protective Coatings (SPC), we pride ourselves on our expertise in surface preparation and the application of protective coatings across a wide range of sectors, including Rail, Highways, Defence, Petrochemical, Energy, Structural Steel, and Infrastructure. One of our recent projects for Blackwater Manufacturing involved the coating of gas pipes, where precision, durability, and efficiency are of utmost importance. This is our coating process.
Pre-Blast Preparation
The first step in our coating process is preparation before blasting. Upon receipt of the pipes we thoroughly inspect all steel pipework for any abnormalities that could affect the blasting/coating process. The detailed inspection process is to identify oil, grease, laminations in the steelwork, heavy pitting in the steelwork or other imperfections. Once the inspection is complete and the pipework has been approved the pipes are blasted.
Blasting
Blasting is an important phase in preparing the pipes, ensuring that the surface is clean and roughened to promote the adhesion of the coating.
External Blasting: The pipes are first sent through our automated blasting machine. This machine propels abrasive materials at high speed against the surface of the pipes, removing any mill scale, rust, and other contaminants. This process also creates a roughened profile on the metal surface, which is essential for the coating to adhere properly.
Internal Blasting: Following the external blasting, the pipes undergo manual internal blasting. This involves a similar process where abrasive materials are directed through the inside of the pipes to ensure they are clean and have a suitable surface profile for the internal coating.
Paint Coating
Internal Coating: After the pipes have been blasted and cleaned, we proceed with the internal coating process. For this particular project, the internal surfaces are coated with 50 microns of a two-component epoxy polyamine cured coating under GIS/CM1 & CM2 standards. This allows for better gas flow and assists in the prevention of rust. SPC ensures that we work to the requirements of the client’s specifications along with those specific to the gas industry.
We employ a “pour and roll” method to apply the internal coating. This involves raising one end of the pipe to a 45-degree angle and pouring the epoxy coating into the higher end. We then slowly rotate the pipe to ensure that the coating spreads evenly over the entire internal surface. Once fully coated, any excess material is allowed to drain out the bottom, ensuring a consistent and even layer.
External Coating: With the internal coating completed and cured, the focus shifts to the external surfaces. For this project, we applied 1500 microns of a solvent-free urethane coating following GIS/CW6 standards.
The external coating is applied in a controlled environment to ensure that the thickness and coverage meet the specified requirements. This thick, durable layer of urethane provides robust protection against environmental factors, mechanical damage, and chemical exposure.
Final Inspection and Quality Control
Once the internal and external coating has been applied, the pipes require a final inspection. Our quality control team checks the thickness of the coatings to ensure that they meet the specified standards and finally, a holiday detection inspection is completed to ensure the coating is free of defects. We are looking for the pipes to not only be protected against corrosion and environmental damage but also fulfil the industry requirements for the operation of gas systems.
Daniel Littlewood, paint inspector at SPC, said: “This project has demonstrated our commitment to precision, durability and efficiency at every step of our process. Our team’s commitment to excellence guarantees that the coated pipes will withstand the harsh conditions they are exposed to and contribute to the reliability and safety of the gas plant’s infrastructure.”
At SPC, we are committed to delivering high-quality coating solutions that meet the specific needs of our clients. Our meticulous process ensures that every component we treat is prepared and coated to the highest standards of durability and performance. Whether in the Rail, Highways, Defence, Petrochemical, Energy, Structural Steel, or Infrastructure sectors, our expertise ensures the longevity and reliability of critical infrastructure components.
