The Problem
A power plant’s domestic water tank exhibited severe external corrosion, requiring structural repairs and the application of a long-term protective coating system. Due to the tank’s continuous exposure to UV radiation, it also required a UV-stable, heat-tolerant topcoat capable of preventing premature coating degradation.
Abrasive blasting was not a viable surface preparation method due to the high costs associated with containment, encapsulation, and the removal of existing lead-based paint coatings.
The Application
NanoPrep was selected as the preferred surface preparation method as it provided an effective and cost-efficient alternative to abrasive blasting. Surface preparation was completed using a combination of low-pressure power washing (3500 psi) and power tool cleaning, eliminating the need for costly containment and lead paint removal procedures.
Water Tank Corrosion Protection Without Blasting
Before coating work commenced, several structural repairs were required due to severe corrosion damage. The tank underside had extensive pitting, while some of the steel column supports had deteriorated to the point where sections of steel were completely missing.
Belzona 1111 (Super Metal) was used to repair the pitted areas on the tank underside, rebuild lost steel sections, and cold bond reinforcement plates onto the damaged steel supports, restoring structural integrity without the need for hot work.
Once the repairs had fully cured, the steel supports and surrounding areas were coated with two coats of NanoPrep, followed by two coats of R230 TopCoat.
The tank sides and roof were also protected using NanoPrep and R230 TopCoat. Again, surface preparation required only high-pressure water washing, eliminating the need for abrasive blasting. Brushes and rollers were used to stripe coat weld seams, edges, and difficult-to-access areas prior to spray application.
Two coats of NanoPrep and two coats of R230 TopCoat were then applied by airless spray, providing long-term corrosion and UV protection. Both products proved highly user-friendly due to their single-pack formulation, allowing for efficient and straightforward application.
Water tank underside showing corrosion and pitting damage
Belzona 1111 was used to repair pitting and reinforce corroded areas
Belzona 1111 used to repair corroded steel supports
Rebuilding of metal loss on steel supports using Belzona 1111
Reinforcement plates cold bonded onto the damaged steel supports with Belzona 1111
Corroded tank underside and steel supports before repairs
Tank underside and steel supports after application of NanoPrep
Tank underside and steel supports after application of R230 TopCoat
NanoPrep applied by roller to stripe coat weld seams, edges, and difficult-to-access areas
NanoPrep applied by airless spray
Tank roof before application of NanoPrep
Tank roof after application of NanoPrep
Tank roof following application of R230 TopCoat, providing a durable, long-term corrosion and UV protection solution
Corroded tank underside and steel supports after application of NanoPrep and R230 TopCoat
Completed domestic water tank following application of the NanoPrep coating system and R230 TopCoat, providing a durable, long-term corrosion and UV protection solution
The Outcome
The project was successfully completed in just five days, with severely corroded areas repaired using Belzona and protected with NanoPrep and R230 TopCoat.
By eliminating the need for abrasive blasting, the project avoided the high costs and delays associated with containment and lead paint removal, while still delivering a durable, long-term corrosion and UV protection system for the tank and supporting steelwork.
Project Specification
| Item | Detail |
|---|---|
| Industry | Power Generation |
| Application | Water Tank Corrosion Repair & Protection |
| Products | NanoPrep, R230 TopCoat, Belzona 1111 |
| Location | NSW, Australia |
| Application date | Dec 2025 |
| Duration | 5 days |
| Surface preparation | Low-pressure power wash (3,500 psi) + power tool clean — no blasting |
| Key requirement | No blasting, lead paint encapsulation avoided, UV-stable topcoat |
