What is an ARC coating, and when is it the only durable solution for chemical exposure in the process industry?

In industrial environments, machinery and structures are constantly exposed to harsh conditions. Piping, tanks, mixers, and tanks in the process industry come into daily contact with strong acids, bases, solvents, and abrasive slurries. Traditional carbon steel or conventional paints deteriorate rapidly in these applications. The result is often unplanned downtime and a continuous cycle of costly repairs.

Specialized composite technologies have been developed to protect these challenging applications. The best known of these are high-performance ARC composite coatings. These specialized materials provide exceptional protection when other coating options do not guarantee a sufficient service life. For engineering and maintenance experts, ARC coating is a reliable solution for extending the service life of process equipment.

What is ARC composite coating?

ARC (Advanced Reinforced Coatings) is based on composite technology that utilizes high-quality polymer matrices and reinforcing materials bonded to them. The typically solvent-free epoxy or polyurethane resin is modified with highly durable fillers, such as silicon carbide, aluminum oxide, or glass flakes.

Behind the technical terms lies a clear practical benefit. The material’s 100% dry matter content ensures that the coating contains no volatile solvents. Therefore, the coating does not shrink as it dries, which prevents the formation of microscopic cracks and pores. The result is a completely dense and impermeable protective film. It prevents aggressive chemicals from penetrating the substrate.

Ceramic reinforcements make the soft polymer surface extremely hard. When a mixer blade or pump housing is protected with a silicon carbide-reinforced composite, abrasive particles in the fluid flow cannot wear away the metal. This solution effectively protects equipment from erosion and cavitation, thereby reducing maintenance costs.

Extreme stress – When do steel, traditional floor coatings, or polyurea reach their limits?

Industrial surface treatment involves the use of many high-quality materials, each of which has its own optimal application. Spray-applied polyurea works excellently in applications requiring flexibility, crack bridging, and rapid curing, such as retention basins and roof structures. However, polyurea always requires a completely dry substrate. It also cannot withstand long-term exposure to concentrated inorganic acids or strong solvents at high temperatures.

Stainless steel provides a good basic level of protection in process equipment. However, in environments with high chloride concentrations or extremely low pH levels, even stainless steel is quickly susceptible to pitting and crevice corrosion. When chemical stress is combined with mechanical flow or erosion caused by solids, the metal surface wears through quickly.

Standard concrete floor coatings can withstand even heavy forklift traffic and common cleaning chemicals. However, when it comes to a sulfuric acid tank sump or a chemical mixing tank where the pH drops close to zero and the temperature rises, standard epoxies and polyurethanes fail. They begin to carbonize, become brittle, and peel away from the substrate.

These applications require a material that is chemically inert and extremely hard. ARC coating was developed specifically for these most demanding conditions. It withstands continuous immersion in concentrated sulfuric acid, lye, nitric acid, and strong organic solvents, even under hot process conditions where metals and conventional coatings fail.

Key Applications of ARC Coating in the Process Industry

There are numerous applications in industry where traditional anti-corrosion paints or thin protective coatings cannot withstand the combined effects of chemicals and mechanical stress. For example, in the pulp, paper, and chemical industries, as well as in mining and energy production, premature wear of process equipment causes costly production downtime. ARC coating solves these most demanding challenges.

One of the most common applications is in industrial mixers and pumps. When abrasive solids, such as sand, fibers, or metal particles, are mixed into a liquid, severe wear occurs. Coatings reinforced with ceramic fillers withstand the stress caused by this continuous mechanical impact and high flow velocity. As a result, the pump housing and impeller retain their shape and hydraulic efficiency for significantly longer. Equipment maintenance intervals are extended, which improves the operational reliability of the entire process and saves maintenance resources.

Another key area of focus is chemical storage tanks, reactors, and their drainage and containment basins. When storing sulfuric acid or strong bases, even a small leak or damage to the coating poses a serious safety risk and damages the surrounding concrete structures. Composite materials designed for demanding chemical applications form a completely impermeable protective layer that does not soften or dissolve even under the influence of strong chemicals. The structural integrity of tanks and basins remains reliable for decades in these applications.

The key to successful coating: Careful preparation and quality control

No coating material will perform as expected without thorough surface preparation. In composite coatings, the importance of substrate pretreatment is further emphasized, as the material’s exceptional bond strength is based on mechanical anchoring to a clean surface.

Steel surfaces are blast-cleaned to a cleanliness level of Sa 2½ or Sa 3 in accordance with ISO 8501-1. In addition, a sufficiently large and sharp-edged roughness profile is created on the surface. Sufficient roughness ensures that the liquid composite adheres to microscopic grooves and forms a tight bond with the steel. This prevents the coating from flaking and peeling during rapid temperature fluctuations, where materials expand at different rates. If surface preparation is inadequate or salts or grease remain on the surface, the coating is prone to damage under demanding operating temperatures.

Quality control is an integral part of the professional coating process. The film thickness of the finished surface is always measured, and a spark test—a high-voltage test to verify the absence of pores—is performed. This reveals microscopic pinholes invisible to the naked eye. Any defects can thus be corrected before the surface is put into service. This method prevents pitting corrosion and stops chemicals from penetrating metal structures.

High-quality protection is an investment that pays for itself by extending the service life of equipment and reducing maintenance costs. Protective composite coatings can reduce maintenance costs for process equipment by as much as 50–60% over a ten-year period. This represents a significant savings compared to repeated equipment repairs or part replacements. Protecting mixers and chemical tanks with a material that withstands extreme conditions ensures uninterrupted production, improves workplace safety, and prevents unplanned, costly downtime.