Waterproofing & Protective Coatings for Process Plants
Process plant work is protective coating engineering as much as waterproofing: containment bunds, equipment foundations, trenches, sumps and structures exposed to both weather and process chemistry. Specification is driven by chemical resistance, temperature and inspection access.
A projects or maintenance engineer at a chemical, pharmaceutical, food or utilities plant.
What actually makes this difficult
The technical work overlaps with every other kind of building. The constraints are what differ, and they are what a contractor either understands or does not.
- Process chemistry
- Resistance requirements are specific and non-negotiable.
- Statutory containment
- Bunds must hold their design volume and be demonstrably impermeable.
- Permit-controlled work
- Hot work, confined space and isolation procedures govern the method.
- Inspection regimes
- Linings must be testable — spark testing, thickness, adhesion.
How we work on these projects
- Specify against the actual process chemistry, concentration and service temperature.
- Work strictly within your permit-to-work system.
- Holiday and spark testing on containment linings, with records.
- Documented dry film thickness and adhesion testing across the area.
Systems this kind of project usually needs
- FRP Lining Waterproofing
FRP lining waterproofing bonds layers of glass-fibre reinforcement saturated with resin onto a prepared substrate, curing into a hard, seamless, chemically resistant shell. It is used where the lining must resist chemical attack and mechanical damage as well as water — tanks, bunds, channels and industrial containment..
- Polyurea Waterproofing
Polyurea is a spray-applied, fast-setting elastomeric coating that gels within seconds and forms a seamless, high-elongation, highly abrasion-resistant membrane. Because it has no joints and builds thickness in a single pass, it suits complex geometry and structures that must return to service quickly — tanks, podiums, parking decks and pools..
- Chemical Coating
Chemical coating is the application of a liquid chemical-based protective barrier to concrete or masonry, forming a continuous film that resists water penetration and chemical attack. Product selection is driven by the exposure it must survive rather than by appearance..
- Solvent Based Coating
Solvent-based coating uses organic solvents as the carrier, producing a hard, dense, chemically resistant film with strong adhesion and good performance in demanding industrial exposures. It requires proper ventilation and trained handling during application..
- Injection Grouting
Injection grouting forces a cementitious or epoxy grout under pressure into cracks, voids and honeycombed concrete to restore continuity and block water paths. Cementitious grouts fill larger voids economically; epoxy grouts bond structurally and are used where the repair must carry load across the crack..
- Column & Beam RCC Work
Column and beam RCC work is structural concrete repair to a building's primary frame — cutting out distressed concrete, treating or replacing corroded reinforcement, and rebuilding the section with polymer-modified repair mortar or micro-concrete. It is structural work and must follow a proper diagnosis, not a visual guess..
Process Plants — questions we get asked
How do you demonstrate a bund lining is sound?
Spark or holiday testing across the lined area to find pinholes, dry film thickness readings on a grid, and adhesion pull-off tests. All three are recorded and handed over.
Can lining work be done without a full plant shutdown?
Often it can be isolated to one bund or trench at a time. The controlling factors are ventilation, hot work restrictions and safe isolation, not the coating itself.
What if we do not know the exact chemical exposure?
Then we do not specify. Guessing at resin chemistry produces a lining that fails in service, sometimes dangerously. We ask for the datasheet or a conservative worst-case.
We also work with
Talk to us about your process plant project
An engineer visits, identifies the actual source, and gives you a written scope you can act on. 40+ years of Mumbai buildings.
Mon–Fri 08:00–18:00 · Sat 09:00–16:00 · Jogeshwari West