Petrochemical & Chemical Processing Coating & Repair Services

Stored chemicals go after tank floors and the floor-to-shell weld. Steel thins wherever stagnant product settles and the old lining has worn through. We apply a cold-cure lining as one continuous film over the prepared interior, and the tank comes back with no welds to recoat and no heat soak. The same approach lines process vessels, knock-out drums, and separators that corrode at welds and access ports, and it seals the tank-to-foundation chime where rainwater wicks in and attacks the floor plate from beneath. Hot equipment that cannot be cooled or drained gets a high-temperature immersion lining matched to the actual service temperature, cured cold on the operating surface.

Scrubbers and absorber towers take acidic condensate that thins shell steel at the internals and the liquid distribution zone. We line the tower interior with a chemical-resistant cold-cure system during the scheduled outage, with no hot work anywhere in it. Ceramic-filled coatings carry the combined erosion and chemical load on cyclone cones, fan blades, or amine-system surfaces. Our crew rebuilds the worn geometry first, then overcoats it, and the unit recommissions on its design curve inside the same window.

Containment is where a chemical leak becomes a reportable event. Bund walls spall from the inside out, expose rebar, and open cold-joint cracks until the wall stops holding its rated volume. We rebuild the spalled face, cap it with a barrier coating, and add a chemical-resistant overlay where the spill chemistry demands it. No demolition, no recast. Across the broader containment zone, the crew lines porous concrete and cracked joints with a system matched to the worst-case spill. The facility holds the volume its SPCC plan requires.

Process floors and containment areas take acid, alkali, and mechanical load that strips ordinary toppings right off. We lay a chemical-resistant floor over prepared concrete or steel that survives the worst-case spill underneath and the forklift traffic on top. Acid-retaining walls, drains, and channels get the same chemical-resistant treatment over prepared concrete, so the structure holds the stream with no slab break-out. Spalled slabs and deep concrete loss get rebuilt cold, from crack patching to bulk fill, and exposed rebar is cleaned and primed first to stop the corrosion cycle that drove the original spall. Where static is a hazard near flammable atmospheres, we install a static-dissipative floor that bleeds charge to ground.

Pipework in these plants corrodes from the inside and the outside at once, and the worst metal loss gathers at bends, tees, and elbows where flow turbulence drives it. We line and wrap the contoured fitting with a composite that follows its geometry, so the spool stays right where it is. Through-wall corrosion and external pitting on pressurized pipe take an engineered resin and fiber composite wrap applied with the line still online. The wrap is designed to the methods recognized in ISO 24817 and ASME PCC-2 and returns the pipe to its design pressure rating. For external corrosion at supports, girth welds, and coating gaps, the crew preps the steel and applies a cold-cure protective coating that resets the corrosion clock without taking the line down.

Active leaks do not wait for a shutdown. We seal them cold with the line still pressurized, then overwrap for the permanent fix. No product evacuation, no hot work. A flange face weeping at the gasket joint gets encapsulated in a cold-cure compound that seals the joint and protects the seized bolting, leaving the assembly free for future disassembly. Pinholes and corrosion pits on wet or product-contaminated steel are rebuilt with compounds that bond to damp, contaminated surfaces. Low-friction liners at pipe supports let the line move and shed water, and anti-seize coatings on hot bolted assemblies mean the next teardown breaks free clean.

Every repair here does the same two things. It keeps the asset in service, and it keeps hot work off the permit list. The vessel, the tank, the containment wall, and the pressurized line all come back during the outage already scheduled, not the one a fabrication lead time would force on you. That is what Texas Gulf Coast refiners, petrochemical producers, and marine operators are actually buying: the downtime they avoid and the unplanned shutdown they never have to take.

BHI Coatings backs it with a climate-controlled shop for components that come off the unit. A field crew mobilizes on 24-hour call across the Texas Gulf Coast. The work draws on decades of turnaround experience, a strong safety record, and factory-trained and factory-certified Belzona applicators on every job. The crew shows up, gets the surface prep right, and puts the equipment back to work.