Hollow Core

Hollow Core grouting systems for cooling towers

  • Eliminate steel corrosion.
  • Stop water and chemical leaks.
  • Extend the service life of your cooling tower or condenser for many years.
  • To withstand the harsh attack of cooling tower chemicals
  • Harsh – Chemical attack – High or low pH – Vibration – Excessive Flexing
  • Commercial Buildings – Industrial – Cold Storage – Food and Beverage

RepelCoat Grout GSW-200.

For sealing / repairing hollow cores in steel fiberglass or concrete.

Hollow cores allow water and chemicals to go where they should not or they bacteria such as the Legionella Bacteria to live and multiply within the hollow core.

Chemicals leak out of a cooling tower and onto the ground for example. Once on the ground the chemicals travel to our rivers, creeks and bays damaging the environment.

The BAC RCT or PCT cooling tower has hollow legs that can be sealed by coating interior seams and joints but what if the unit is an evaporative condenser or fluid cooler?

There is no interior access if a coil is installed so seams and joints cannot be sealed where the coil is bolted into the casing.

This is an example where the RepelCoat Grout GSW-200 system is used to fill the hollow legs, to stop the chemical leaks. It also stop bacterial growth.

Our technician mixing the RepelCoat Grout GSW-200 coating products prior to the hollow core application.

Pouring the RepelCoat GSW-200 grout coating mix into the evaporative condenser hollow core leg to stop water and chemical leaks around the steel coil that is permanently bolted into the casing.

Removing the air bubbles from the RepelCoat Grout GSW-200 coating system

Grout is commonly associated with filling gaps between tiles, but grout also has a major role in solving cooling tower repairs. FlowMatrix had developed RepelCoat Grout to repair cracks in concrete pits, repairing sections of concrete that have fallen off concrete plinths or general cracks.

Our latest innovation is RepelCoat Grout for filling cooling tower hollow cores. Modern BAC RCT and PCT cooling towers and condensers are built with hollow fiberglass legs that leak water and chemicals after the internal casing sealant fails. Condensers and fluid coolers have coils fitted so it is impossible to seal the interior casing seams as the coils are in the way. Filling the hollow core with RepelCoat Grout is a fantastic solution as it seals the hollow legs once and forever.

Completely grout filled cooling tower leg.
Example of a leaking cooling tower hollow leg

RepelCoat is a registered trademark of FlowMatrix in Australia.
Formed in 2018 RepelCoat coating products are designed to provide specialized coating systems for cooling tower installations, cooling tower repairs, water leak sealing, pipework, steel supports, plant room floors, roof surfaces under cooling towers, pipework penetrations through floors and roofs, Cool store panel sealing and grouting systems for concrete plinths, or hollow core filling.

RepelCoat coating system range.

The challenge with cooling tower related coating requirements is that the product selected must be able to withstand, chemical attack, high or low pH levels, corrosion, erosion from fast moving water and grit, vibration, excessive movement, foot traffic, and a variation of materials such as steel / copper / fiberglass / plastic.

RepelCoat Rapid RCR-200 / 300 / 400. These systems are used for coating the interior of mild steel, stainless steel, and fiberglass cooling towers. Structural steel supports. Steel ductwork and fan discharges. The amazing thing about this system is the two-hour curing time between coats which is a great time saver for our clients. Submerged applications

RepelCoat PV-300 / 400. These systems are used on pipework, vessels, tanks that are associated with cooling towers or refrigeration systems. Non-Submerged

RepelCoat PUME-200 Membrane coating system for concrete, steel and cool store panels.

RepelCoat Grout GSW-200 for sealing / repairing hollow cores in steel fiberglass or concrete.

RepelCoat MP-100 Submerged concrete resurfacing repair.

For the application of the RepelCoat systems our personnel are trained in using the correct PPE, ventilation procedures, the application of the products, and hazard control.

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