Coatings for Cooling Towers and Coolroom Repairs.

Did you know that cooling towers go through a lot in their lifetimes? Everything from harsh chemicals, extreme temperatures, and rough daily movements from the fan drives and pumps. Indeed,…

Coatings for Cooling Towers and Coolroom Repairs.

Did you know that cooling towers go through a lot in their lifetimes? Everything from harsh chemicals, extreme temperatures, and rough daily movements from the fan drives and pumps. Indeed,…

Coatings for Cooling Towers and Coolroom Repairs.

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Did you know that cooling towers go through a lot in their lifetimes? Everything from harsh chemicals, extreme temperatures, and rough daily movements from the fan drives and pumps. Indeed, if a cooling tower could talk what would it say? I am leaking, I am dirty, corroding, running too hot,…

Why Brentwood Parts are good for all types of Cooling Towers

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Are you looking to replace a part such as fill pack, drift, or mist eliminators for your cooling tower? Not sure what you’re looking for or just looking for alternative supplier options? We sat with the owners of FlowMatrix, the cooling tower specialists Darren, Jason and Landon, who have more…

Coatings for Cooling Towers and Coolroom Repairs.

Did you know that cooling towers go through a lot in their lifetimes?

Everything from harsh chemicals, extreme temperatures, and rough daily movements from the fan drives and pumps.
Indeed, if a cooling tower could talk what would it say?

I am leaking, I am dirty, corroding, running too hot, too cold, have a terrible case of the jitters, have a bad disease, I’m about to explode.

All jokes aside cooling towers can’t talk, nor will they magically tell you what is wrong or what they need and that is why they need to be expertly inspected and repaired on a regular basis.
On top of this, it’s also essential to have a proper coating method (namely RepelCoat) that is designed for all types of cooling towers and materials to protect cooling towers, structures, and people.

We sat with the owners of FlowMatrix Darren and Jason, who have more than 33 years of experience in the cooling tower industry, to be able to better understand the space of cooling towers and more specifically why using RepelCoat will save your cooling tower, structures, buildings, and lots of money.

RepelCoat for Cooling Towers, Cool Rooms, and Structures:

Cooling towers come in all shapes, sizes, and variations of materials such as steel, fibreglass, timber and plastic. It is therefore important that a coating product “RepelCoat” was going to withstand, a chemical attack, high or low pH levels, corrosion, erosion from fast-moving water and grit, vibration, excessive movement, and foot traffic.
In 2018, FlowMatrix in Australia took a big step forward in terms of developing their coating system just for cooling towers, they called it RepelCoat, a registered trademark

RepelCoat consists of a range of coating products all designed to provide specialised coating systems for

  • Cooling tower flexible coating for installations
  • Cooling tower steel repairs to stop corrosion and leaks
  • Fibreglass cooling tower repairs to stop leaks and repair cracks/holes
  • Sealing water leaks in basins pits and tanks
  • Protecting pipework from chemical damage
  • Stopping steel support corrosion
  • Cooling tower plant room floors membranes
  • Steel roof surfaces under cooling towers membranes to stop corrosion and leaks
  • Pipework penetrations sealing through floors and roofs to stop water damage below
  • Cool store panel sealing
  • Grouting systems for concrete plinths and fibreglass to stop water leaks and damage, hollow core filling of cooling tower legs in cooling towers with coils .

Why Experience and Knowledge Counts:

When it comes to cooling towers, FlowMatrix has an abundance of knowledge and experience, having expanded across many fields. They don’t just service and repair cooling towers, instead, they utilise their knowledge and technical expertise to help companies get the best possible outcomes, all from designing the best range of coating systems for each situation and cooling tower type.

Darren explained just how severe and volatile cooling towers are, comparing the conditions to a marine setting, where waves and salt water completely ruin timber structures and metal structures, concrete and fibreglass over time.
Conditions inside a cooling tower are very tough on the unit and what splashes out or what comes out of the fans damages everything around it
“Cooling towers need various coatings on their surfaces to help prolong life and to also keep them running optimally both the unit and the materials around them”.

Having worked with every type of cooling tower for over 33 years, Darren and Jason believed there was nothing out there that genuinely provided a complete solution for any type of cooling tower, the type of installation, the mechanical parts, the supporting structures, the rooftops, plant rooms, pipework and more.
There was also nothing that offered a range of solutions to maintain an appropriate atmosphere, free of corrosion, bacteria, disease, damage and stress

Jason has a 10 years of cooling tower water treatment chemistry background as well as 3 years of specialized coating experience to go with his 8 years of cooling tower experience, so he understood more than anyone what causes all of the common cooling tower problems, and what was therefore required to bridge this gap.
Jason’s all-around knowledge, combined with Darren’s 33 years of cooling tower expertise, experience, and knowledge, FlowMatrix was able to produce and design the highest quality coating system formulations on the market today to combat all of the common cooling tower problems that cause so much grief.

Benefits Of Cooling Tower Coatings:

RepelCoat effectively protects against corrosion and is suitable for all steel cooling towers, including BAC (Baltimore Air Coil), Coolmaster, Evapco, F Muller, Fibreflow, Linear, Marley, Muller and Radic.
RepelCoat effectively repairs and protects fibreglass cooling towers including BAC (Baltimore Air Coil) Evapco, Aquacool, Super chill, Sulzer, Tencel, Tower Thermal, Shinwa, Coolboy, Lakeside

Other benefits include:

• Long-term corrosion and erosion protection
• Good compressive strength
• Not affected by biocides such as chlorine
• Great resistance to a wide variety of chemicals and high or low pH
• Reduced safety and health risks due to being clean and smooth finished surfaces
• Allows expansion, does not shrink or distort
• Can be cured and applied at room temperature within 2 hours
• Includes surface preparation to AS 1672.4
• Leaves an extremely hard-wearing long-life surface
• Bonds to steel will not lift away; any physical damage will be localised to the affected area
• Designed to withstand cooling tower water treatment programs
• Able to withstand high or low pH, high salt levels, acid, alkaline
• Reduces the growth of Legionella bacteria by eliminating corroded surfaces
• Stops water and chemical leaks into the environment
• Extends the life of the cooling tower by many years

Where you can use RepelCoat:

RepelCoat coatings can also be placed on the cooling tower’s exterior/interior, providing a durable barrier that adheres to steel, fibreglass, timber, and concrete, and repels corrosive substances. RepelCoat prevents corrosion and rust on the inside and outside of your cooling tower, as well as piping, penetrations, vessels, and concrete bases. A tank can be protected inside and outside to avoid corrosion and leaks, extending the life of your equipment.

Pipework

A specialised coating method is required for cooling tower pipework.
RepelCoat is a line of cooling tower coating solutions created by FlowMatrix.
Cooling tower water and chemicals are splashed and sprayed onto pipework which causes existing coatings to fail, severe corrosion and pitting of steel, damage to stainless steel, concrete supports and floor steel reinforcement failure (concrete cancer), plastic pipe sunlight damage when coatings fail, and copper corrosion.
Pipes can fail and burst, crack and leak treated water into a plant room, onto a roof, or the ground. It costs a lot of money to replace damaged pipework and it can take weeks to cut the damaged section and valves out, and then replace it. What a pain!

The preparation and coating of steel, copper and PVC pipework connected to cooling towers are one of the RepelCoat systems.Hollow-core filling

Grout is most frequently associated with filling gaps between tiles, but it also plays a significant role in cooling tower repair. RepelCoat Grout was created by FlowMatrix to fix cracks in concrete pits, parts of concrete that had fallen off concrete plinths, general concrete fractures in pits and now to repair hollow cores in fibreglass basins and leaking hollow legs in BAC cooling towers

Coolrooms

The cool room panels must be sealed to save money on operations. If the panels have gaps, the cold air can easily escape into the outside air. This causes ice to form in the fractures, weakening the panels by causing more significant gaps and buckling as the ice spreads. The harder the refrigeration system is forced to function, the more gaps and panel damage appear. The RepelCoat Sealing system includes surface cleaning, etching, primer coat, and topcoat. It’s a membrane system that clings firmly to the panels while being flexible enough to allow for slight panel movement due to expansion and contraction. Hundreds of thousands of dollars of refrigerated air are wasted every week from cool store panels that leak the cold air out into the surrounding warm air. It is a stupid waste of electrical energy that bumps up an operator’s power bills, causes the refrigeration equipment to run harder and wear out quicker, and the loss and cost of expensive refrigeration gas

If FlowMatrix notices that there are other potential issues with your cool room that go beyond coating systems, they can use their expertise to refer you to a company that can help you. Darren mentioned that they frequently refer all their clients to Coolclean, a Victoria-based company that provides cool room cleaning, maintenance, repairs, and services for cool room surfaces, fan coil units, evaporators, Penthouse units, and banana rooms and Alcoves.

You can check out their page here to see if they offer what you need
https://www.coolclean.com.au/RepelCoat can also be applied to the following cooling tower systems: Collection Basins, Chilled Water Tanks, Packaged Towers, Field Erected Towers, Distribution Decks, Chiller Plants, and Ice Storage Tanks.

RepelCoat coating system range:

The FlowMatrix team use their knowledge and experience to create a tailored coating system coating for each tower and job type.

Darren explained as an example, “in a steel cooling tower, there will be 3 systems for different jobs
• one that bonds to the steel base
• another to create flexibility
• and a chemical protectant coating

And so, we would recommend the most appropriate coatings for each cooling tower, system, and site.Here is the range of RepelCoat systems that could be useful for you:

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

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

RepelCoat PUME-200 /300 Membrane concrete plant rooms, steel flooring or steel roofing coating systems.

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

RepelCoat MP-100 Submerged concrete repair and resurfacing of pits and tanks.

Application process:

The FlowMatrix team use their knowledge-creating a tailored coating system for each tower;

Steel interior surfaces of cooling tower basins, casings, and walls. Tank interior surfaces. FlowMatrix disassembles steel panels, opens up access hatches and carries out a confined space entry procedure to gain complete access to carry out the RepelCoat coating system. Surface preparation is by sand / abrasive blasting or by hand preparation using bristle blasters, grinders and wire wheeling. This is the critical stage to get the surface clean and ready for a fantastic bond with the RepelCoat primer
The application of the primer is critical to ensure that the bond is sound, so mixing the products correctly must ensure the correct curing rate based on the temperature of the day and the humidity.
The mid-coat is a specialized product that bonds to the primer and the top chemical-resistant coating to allow movement without cracking the RepelCoat system. This is critical as cooling towers move, shake and vibrate due to the fan drives, water hammers from pipework and pumps, and maintenance people walking on the surfaces
The top chemical resistant coating is there to withstand the constant attack from chemicals, acid, alkaline, hard water, soft water, high pH, low pH, corrosion inhibitors, biocides, sodium hypochlorite, chlorine, erosion from water and dirt pounding against the surface like sandblasting
Fibreglass is a two-coat system with the primer being the flexible coating layer and the top coat being the chemical-resistant coating. All the aspects of the steel system apply except the primer/bonding is a different chemical reaction and bonding process

The following video is FlowMatrix application process:

If you need an expert to take a look at your cooling tower, cool room, equipment, any component that is not working, or if you simply need the best advice to get the longest life and best results from your cooling system, then give FlowMatrix a call.

The entire team are very knowledgeable and will most definitely be able to assist you.

Why Brentwood Parts are good for all types of Cooling Towers

Are you looking to replace a part such as fill pack, drift, or mist eliminators for your cooling tower? Not sure what you’re looking for or just looking for alternative supplier options? We sat with the owners of FlowMatrix, the cooling tower specialists Darren, Jason and Landon, who have more than 33 years of experience in the cooling tower industry, to be able to better understand the ins and outs of cooling towers and, more specifically, why using Brentwood’s parts in your cooling tower should be a no brainer.

 

FlowMatrix imports Brentwood parts into Melbourne and Sydney from the USA factory and Thailand factory as fully formed PVC blocks to Australia. These parts are multi-purpose as they can be installed in cooling towers, sewage treatment plants, stormwater systems, ventilation, and gas scrubbing scrubbers.

 

Why Brentwood Parts?

FlowMatrix puts their trust in Brentwood parts as they trust the integrity of the manufacturer Brentwood Industries which has produced high-quality products for OEM and installers for decades. The blocks and sheet materials are made to a high standard, have the correct fire rating, are traceable to recognised international standards and Australian standards such as AS / NZS 3666, have supporting information with product datasheets, and have been designed with engineering expertise.

Brentwood PVC materials are engineered to be strong, lightweight, UV stabilised, modular, and fire-resistant. These factors will contribute to a longer life of around 10-20 years for your cooling tower. It seems to be a simple choice if you want your fill pack and drift eliminators to last for many years instead of a couple of years for which the cheap copy lasts.

The cheap plastic fill pack and drift eliminator products that many significant companies use and install to keep the price down in many new cooling towers can cause systems to clog up, shut down and fail after only 2-3 years if the material breaks up into particles. Out of warranty systems, experience blocked inline suction strainers, plastic fragments in heat exchange tubes, and in pipes.

Worse than this, some of the cheap plastic damages other components such as nozzles, grommets, water distribution systems, filtration units, and chemical dosing equipment. This can be severe, costing a lot of money to fix or replace.

Darren told us that “a lot of these cheaper parts or plastic sheets coming out of China are a big problem for the cooling tower units in which they are installed”.

However, there is another problem even getting these parts now as there is a big backlog due to them being on hold as Shanghai is in lockdown.  Landon told us that in Sydney, there are a lot of crossflow cooling towers with sheet fill pack that is terrible to remove as it is not modular.

The good news here in Australia is that Flowmatrix can continue to import their cooling tower parts from America and Thailand, being able to continue with their repairs and installations with little waiting times or delays.

Why Do Some People Bother Installing Cheap Parts?

They do not know any better as the sellers of cheap cooling tower parts advertise that they are compliant and just show a short two-line statement or a one-page certificate that they comply with an Australian Standard.

As FlowMatrix said to us, the quality Brentwood cooling tower fill pack and drift eliminators have not just Australian Standard compliance such as AS/NZS3666 and AS4180, but international standards for the PVC material they are made of, the details of the UV protection, cooling performance data sheets, fire rating datasheets, and assembly technical information sheets.

Buy Brentwood parts to last for years, or buy cheap to watch it, break up, fall apart, shrink in warm water, or burn down if a spark gets on it.

Believe it or not, “quality parts like Brentwood cost only around 15% more to purchase and install, than low-quality ones, and on top of this, Brentwood Parts will save you more, in the long run, reducing high-risk situations and even providing your cooling tower with a few extra years.”

Brentwood Parts can be used for other applications

We also discovered that Brentwood supplies parts for many applications such as clean high, performance air-conditioning installations, industrial applications, storage, and cold storage. There are Brentwood parts to suit dirty water industrial installations, sewage treatment applications, parts for gas scrubbing where gases are removed from the air in process systems, ventilation systems, and storage sheds for potatoes, mushrooms, and chickens to allow clean air flow blocking out sunlight.

Brentwood parts are also commonly used for a range of other things such as garages, sunlight banks on potato sheds, light banks to protect produce and water treatment facilities

Find the right part for your cooling tower

Finding the right cooling tower part for you can be confusing as there are so many makes, series, and models; it can waste your time! The best part about Brentwood is the details can be used for any cooling tower, new or old!

 

FlowMatrix can design and select the right material to suit your application using products they import and products they hold stock of, such as Brentwood ShockWave, ThermaCross, CF1200, XF75, CFUltra, XF80Max, XF150Max.

To deal with soft or hard water and scale, you require a robust PVC material like Brentwood manufactures as it is strong enough to handle power or pressure water washing/blasting. Brentwood also has a high-performance fill pack that is more open to reducing blockage caused by scale while still cooling effectively.

For example, Melbourne, Sydney, Tasmania and Brisbane has spotless water, which is soft and easy to manage in a cooling tower. Standard parts such as fill pack CF1200 or XF75 and drift eliminator CFUltra, or XF80Max are excellent for these conditions.

In SA, South Australia, Adelaide, Western Australia, Perth, and county towns, have hard water that will scale fill pack and drift eliminators very quickly, so you may consider Brentwood fill pack ShockWave or ThermaCross and drift eliminators XF150Max of CF80Max

 

Brentwood parts can be used for all commercial and industrial cooling towers all over Australia, some of these include

 

Aggreko cooling tower

Aquacool cooling towers MSS or MEC

BAC Cooling Tower, Steel fibreglass, stainless

Baltimore Air Coil cooling tower

Budge Ellis cooling tower
Coolboy cooling tower

Coolmaster cooling tower

Davenport timber cooling tower

Evapco Cooling Tower

F Muller cooling Tower

Fibreflow cooling tower fibreglass
Fibre Tech cooling tower fibreglass

Gatorade cooling tower fibreglass

Hamon cooling towers

Hydrothermal cooling towers fibreglass

Lakeside cooling towers timber, fibreglass

Linear cooling tower
Marley Cooling Tower

Maxichill cooling tower

Messan cooling tower

Muller cooling tower

Shinwa bottle cooling tower

Sulzer cooling tower
Superchill cooling towers

Marley Temcel cooling towers

Thermfresh cooling

Tower Thermal cooling tower

 

             

 Brentwood Drift Eliminator –         Brentwood- Drift emininator

Counterflow CF Ultra                           Crossflow XF 150 

 

Some Major Companies that use Brentwood Parts

Flowmatrix has been able to install Brentwood parts all over Australia to a variety of industrial and commercial company’s some of the most recent projects being:

-BHP

-Australian paper

-BOC

-BlueScope

Manildra

AG Coombs

Lineage

Ellis Air

Precise Air

Johnson Controls  

 

Brentwood Parts Maintenance:

Brentwood parts have been engineered and designed to make all maintenance and repairs as easy as possible.

All parts

  • Are modular components
  • Are easy to install and to remove
  • Easy to repair or replace
  • Easy to remove, clean, maintain, and refit
  • Great in how they are compliant with government regulations, laws and standards
  • Perfect for people that want to get hands on, and do the installation, repair, or maintenance themselves
  • Come with supporting data of all cooling tower maintenance
  • Are fully traceable

Jason points out that “on the other hand, parts from other companies are designed in a way where they are not able to be taken out and thoroughly cleaned especially in places like the basin of the cooling tower.

This means they are not meeting the needs of the regulations and more importantly that their cooling tower can eventually become biologically contaminated, corroded, fouled and scaled.

  Scrubbing material                                    Gas Scrubbing

 

FlowMatrix provides a range of Services using Brentwood Parts

With over 33 years of experience in the Cooling Tower industry, Darren and Jason have 33 pride themselves in using their extensive knowledge to understand their client’s needs.

We found out that FlowMatrix can:

  1. Sell the parts to its customers anywhere in Australia
  2. Or offer a “supply and install” service to those that want a professional, hassle-free, and compliant installation of cooling tower parts or components in Victoria, NSW, the ACT, South Australia or Tasmania.

FlowMatrix also provides a valuable service of recommending the best fill pack and drift eliminator parts to their clients for customers who want to buy Brentwood spare parts. These parts get the best possible results that will benefit their company and cooling towers long term.

FlowMatrix will supply you with all the supporting data like information on cooling tower performance, heat rejection rates and recommending OEM (Original Equipment Manufacturer) products which is everything that will ensure you have everything needed to support a happy cooling tower. Indeed, FlowMatrix is one of the few companies that can provide “supply, sell, and delivery” of Brentwood parts.

 

   Brentwood- Fill Pack- Crossflow      Brentwood- Fill Pack-    

    moduler XF 75 IL&ID                        counterflow  Thermacross TX 19 

                                                                                                                                                                                                                    

 

Great Brentwood Parts and great after sales service:

FlowMatrix also provide a very rare personalised after-sales service level of care to their clients, where Darren or Jason regularly provides assembly, installation instructions at distance, over a mobile call, even a facetime call during a cooling tower part assembly.

Whatever parts or cooling tower needs you have, you should get on the phone and ask to speak to Darren Jason or Landon.

They will listen to your enquiry, ask you the relevant questions, and then arrange for a cooling tower inspection or get a quote on any part Brentwood part you need for whatever cooling tower or problem that you may have.

The guys really know their stuff, and love helping people.

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Great work! We have just had the maintenance contract for the site approved and your work had a lot to do with it.

Mitchell Burge

Director

We call on FlowMatrix to assist with cooling tower repairs at a number of our sites. The FlowMatrix guys are professional, thorough and efficient – they’re very good at what they do and are really communicative throughout

Peter Cooke

Senior Account Manager

Just a brief note to compliment both Jordan and his team.

Apart from the fact that they put in a full day’s work, they are a credit to your organization.

Attitude is everything. Nothing is too much of an issue.

Great team.

David Niezen

Facilities Manage

Great work! We have just had the maintenance contract for the site approved and your work had a lot to do with it.

Mitchell Burge

Director

We call on FlowMatrix to assist with cooling tower repairs at a number of our sites. The FlowMatrix guys are professional, thorough and efficient – they’re very good at what they do and are really communicative throughout

Peter Cooke

Senior Account Manager

Just a brief note to compliment both Jordan and his team.

Apart from the fact that they put in a full day’s work, they are a credit to your organization.

Attitude is everything. Nothing is too much of an issue.

Great team.

David Niezen

Facilities Manage

Great work! We have just had the maintenance contract for the site approved and your work had a lot to do with it.

Mitchell Burge

Director

We call on FlowMatrix to assist with cooling tower repairs at a number of our sites. The FlowMatrix guys are professional, thorough and efficient – they’re very good at what they do and are really communicative throughout

Peter Cooke

Senior Account Manager

Just a brief note to compliment both Jordan and his team.

Apart from the fact that they put in a full day’s work, they are a credit to your organization.

Attitude is everything. Nothing is too much of an issue.

Great team.

David Niezen

Facilities Manage

Great work! We have just had the maintenance contract for the site approved and your work had a lot to do with it.

Mitchell Burge

Director

We call on FlowMatrix to assist with cooling tower repairs at a number of our sites. The FlowMatrix guys are professional, thorough and efficient – they’re very good at what they do and are really communicative throughout

Peter Cooke

Senior Account Manager

Just a brief note to compliment both Jordan and his team.

Apart from the fact that they put in a full day’s work, they are a credit to your organization.

Attitude is everything. Nothing is too much of an issue.

Great team.

David Niezen

Facilities Manage

Great work! We have just had the maintenance contract for the site approved and your work had a lot to do with it.

Mitchell Burge

Director

We call on FlowMatrix to assist with cooling tower repairs at a number of our sites. The FlowMatrix guys are professional, thorough and efficient – they’re very good at what they do and are really communicative throughout

Peter Cooke

Senior Account Manager

Just a brief note to compliment both Jordan and his team.

Apart from the fact that they put in a full day’s work, they are a credit to your organization.

Attitude is everything. Nothing is too much of an issue.

Great team.

David Niezen

Facilities Manage

Great work! We have just had the maintenance contract for the site approved and your work had a lot to do with it.

Mitchell Burge

Director

We call on FlowMatrix to assist with cooling tower repairs at a number of our sites. The FlowMatrix guys are professional, thorough and efficient – they’re very good at what they do and are really communicative throughout

Peter Cooke

Senior Account Manager

Just a brief note to compliment both Jordan and his team.

Apart from the fact that they put in a full day’s work, they are a credit to your organization.

Attitude is everything. Nothing is too much of an issue.

Great team.

David Niezen

Facilities Manage

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