Micro concrete projection, butyle rubber coating and anti-acid carbon brick coating of the phosphoric acid reactor R3601A – GCT

The reactor R3601A of GCT Company is a reinforced concrete tank in which the chemical reaction that produces phosphoric acid takes place. 

The reactor is protected by an anti-acid coating in butyl rubber with carbon brick. 

After years of service, the anti-acid coating inside the attack tank loses all or most of its capacity and the concrete will then be attacked by acid. 

The intervention of T.H.I REVETEMENT Company consists firstly in removing the old anti-acid rubber and carbon brick coating, secondly in stripping the contaminated layer of concrete to a depth of at least 10 cm. 

After the stripping and cleaning work, the steel reinforcement of the old concrete is sandblasted and protected with a layer of anti-corrosion paint. 

The next step is the reinforcement of the walls of the reactor with a new rebar reinforcement. 

Following this, the stripped concrete layer is regenerated by the projection of a new layer of micro concrete at high pressure on the new reinforcement. 

Once the new micro concrete layer is projected and leveled, the anti-acid protective coating system is applied, composed as follows: 

– Application of a leveling and signaling coating in special anti-acid resin. 

– Application of a 4 mm thick anti-acid butyl rubber sealing coating. 

– Control of porosity and defects possible on the anti-acid coating by electric holiday detector. 

– Application of a coating in one layer of anti- acid carbon brick for the wall and two layers of anti- acid carbon brick on the bottom.