Devcon Epoxy Coat 7000 AR: Long-Term Tank Protection

Introduction

In the world of industrial maintenance, chemical storage tanks face some of the harshest conditions. One such scenario involved a chemical plant whose primary acid wastewater tank was rapidly deteriorating due to aggressive chemical exposure. The existing protective PVC lining was proving inadequate—requiring frequent repairs, high maintenance, and posing a constant risk of failure. The need for a more durable, chemically resistant, and efficient coating system became paramount.

The solution came in the form of Devcon Epoxy Concrete Sealer and Devcon Epoxy Coat 7000 AR—an industrial-grade coating duo engineered for superior chemical resistance and long-term durability.

The Challenge: Inadequate Protection from PVC Linings

Chemical storage tanks, especially those handling aggressive acids like sulfuric, phosphoric, and hydrochloric acid, demand coatings that offer more than just surface-level protection. The plant’s concrete tank, once protected with PVC lining, suffered constant degradation. The liners not only failed to provide sufficient chemical resistance but also required constant patching and inspection.

Frequent repairs translated into longer downtimes and higher operational costs—not to mention the growing environmental and safety risks associated with potential leaks. Clearly, a more robust and seamless protective coating was needed.

The Devcon Solution: Advanced Epoxy Protection

To overcome these issues, the engineering team at the plant chose a dual-application system from Devcon: Devcon Epoxy Concrete Sealer followed by Devcon Epoxy Coat 7000 AR.

Step 1: Surface Preparation and Sealer Application

Preparation began with surface treatment to NACE (National Association of Corrosion Engineers) standards—ensuring the concrete was thoroughly cleaned and prepped for coating. The Devcon Epoxy Concrete Sealer was then applied using roller brushes. This self-leveling primer bonded seamlessly with the concrete surface, creating an initial layer of defense and acting as a bonding bridge for the topcoat.

Its excellent adhesion not only improved the coating’s lifespan but also helped seal micro-cracks, preventing future chemical ingress.

Step 2: Application of Epoxy Coat 7000 AR

After the primer cured to the recommended recoat time, Devcon Epoxy Coat 7000 AR was applied using a “back roll” technique to ensure a smooth and uniform layer. This topcoat was engineered to withstand the harshest acidic environments.

The application involved one 250-micron coat of the epoxy sealer, followed by two 200-micron coats of the 7000 AR. Critical areas, such as seams and joints, received special attention to ensure a completely seamless, leak-proof finish.

Outcome: Long-Term Durability and Faster Turnaround

The result was a reinforced storage tank capable of withstanding up to 98% sulfuric acid, 50% phosphoric acid, and 36% hydrochloric acid—demonstrating unmatched chemical resistance. What’s more, the entire tank was ready for service within just one week—a remarkable improvement over the long cure times and repeated maintenance associated with the previous system.

Two years later, the tank continues to perform flawlessly with no signs of corrosion, leaks, or coating degradation. This durability has significantly reduced maintenance intervals and associated costs while ensuring safer storage conditions for hazardous wastewater.

Conclusion: A New Benchmark in Industrial Tank Coating

The success of the Devcon solution highlights the importance of using high-performance materials in critical industrial applications. By opting for Devcon Epoxy Concrete Sealer and Devcon Epoxy Coat 7000 AR, the chemical plant not only resolved its immediate issue but also set a new standard for protective coatings in aggressive chemical environments.

Industrial operations looking to reduce downtime, enhance safety, and cut long-term costs should seriously consider epoxy-based coating systems like Devcon's. In sectors where failure is not an option, performance and reliability are everything—and Devcon delivered both.