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Cold Weather Tank Coating Case: Cold weather, especially severe conditions, present problems on two fronts for the oil industry. Firstly, oil has to be kept at a working temperature for transportation and storage, and secondly, coating maintenance work needs ‘ideal’ conditions where conventional epoxies are concerned.

The problem for a major oil and gas exploration company, at a tank farm in Wyoming, was that cold weather makes it extremely difficult to apply conventional epoxy coatings in anything but ideal temperatures, typically at 55 degrees Fahrenheit due to lengthy curing times and the need for the coating liquid to be applied efficiently.

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Tank Coating Case: Greeley, Colorado tank coating company quickly refurbishes oilfield tanks using Castagra’s Ecodur 201.

Colorado oilfields employ many steel tanks that have been in service for several decades. It turns out that some of these oilfields are outlasting these tanks used to collect the oil. A midsized independent oil/gas company has found Castagra’s Ecodur 201 coatings to provide a cost-effective solution to refurbishing old bolted tanks that were assembled and installed many years ago to collect 170 degree F hot oil. This provides oilfield operators a much lower cost alternative to replacing aging tanks.

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Tank Coating Case: A 1,000 barrel content water injection tank for Legacy in Wyoming was badly affected by corrosion. High H2S, sulfur content water at 145 degrees Fahrenheit was being stored. The tank had severe pitting from floor to ceiling. It is common for us to see pits like these on the floor and up the wall 24″ or so, but this tank was pitted all over. It had been fiber glassed and then coated over.

Unprotected fiberglass (Fiber Reinforced Plastic) is highly susceptible to water incursion and/or sun damage depending on the resin used. Water incursion will cause blistering or bubbling, though this typically takes years to show. Once this process starts, extensive delamination eventually occurs further facilitating the movement of water across tank walls.

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Wastewater Tank Coating Case: Rentech, Inc. owns and develops technologies that enable the production of certifed synthetic fuels and renewable power when integrated with certain other third-party technologies.

The Company’s clean energy technology portfolio includes the Rentech-SilvaGas biomass gasication technology and the Rentech-ClearFuels biomass gasication technology, both of which can produce synthesis gas from biomass and waste materials for production of renewable power and fuels. The company has a common problem associated with these processes – wastewater and the safe storage and handling of it.

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Tank Coating Case: At a remote northern Montana location, an American pipeline company required a suitable crude oil tank lining that could be installed and cured quickly at freezing temperatures to minimize operational downtime, while providing long service life for high sulphur “sour” crude oil.

The tank was being constructed late in the year at freezing temperatures and on a compressed timetable to enable it to be placed into service in a very short time frame, right after being coated. Most protective coating materials require substantial time, up to several days, to cure at such cold temperatures.

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Marine Coating Case: World’s largest passenger ferry fleet has 15 year old exterior steel deck coatings still performing well under year round northern Pacific sea conditions.

The British Columbia Ferry fleet operating in the waters off Canada’s Pacific shores is the world’s largest passenger ferry fleet, operating several ships carrying passenger, automobile and freight traffic throughout the network of islands off Canada’s westernmost province of British Columbia. Fleet vessels
including the Queen of Surrey, Queen of Oak Bay and Queen of Capilano have been operating using plasticized gypsum technology since the mid-1990s as protective coatings for the traffic bearing outside steel decks. These coatings have outlasted traditional epoxy coatings by several years and are easily

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Concrete Coating Case: Burnaby, British Columbia commercial concrete building coated with plasticized gypsum in the early 1990s needed little maintenance until eventual repainting almost 20 years later.

Canadian sandblasting and protective coating contractor Sprayaway Enterprises Ltd. applied Castagra’s predecessor industrial coating to all the exterior concrete block walls and the concrete floors of its new building to both complete the building construction process and to provide a protective coating demonstration site. Since then, this company has installed many millions of feet of such coatings on ships, parking garages and buildings.

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Freezer Coating Case (-25 F): A Houston ice creamery has a building type freezer with a concrete door. The ambient temperatures of the approximate 5,000 square freezer area is around minus 25F (-32C). The product is handled using rubber-tired forklifts.

The Houston ice creamery needed to have the floor resurfaced with a coating that would not contaminate food, or involve Volatile Organic Compounds (VOCs) and would only require the minimum of downtime without any need to raise the ambient temperature as would be required for conventional coatings.

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Caribe Resorts Case: Caribe Resorts is a leading resort destination on the Alabama Gulf Coast and needed a coating to prevent guests from slipping as they entered the Lazy River

The Lazy River is made of stainless steel which is very smooth and slippery under water. The challenge was to find a coating that would adhere to stainless steel which was submerged in moving, chlorinated, salt water.

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Martinez Treatment Plant Case (Tempe): Clean drinking water is a highly vulnerable resource that needs protecting both from the security point of view and content. And one of the side-by-side reservoirs needed relining, since it stores treated water from a canal system.

The lay-out of the structure meant that particular attention had to be paid to making the sealing points not only 100% watertight, but also compatible with potable water for the foreseeable future with no leaching of potentially toxic material. Castagra’s Ecodur 201S, with its ANSI/NSF 61 potable rating addressed the problems on three fronts: no VOCs and absolutely non-toxic, permanently exible, and phenomenal bond-ability.

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Rentech, Inc Case: At Rentech’s Commerce City Plant, the conventional coatings were epoxy type and had failed. Tiny cracks and corrosion were starting to form.

Ecodur was used because it stuck very strongly to prepared surfaces and it penetrated existing small gaps and crevices, ensuring complete integrity over the entire treatment area. This is particularly important for areas where there are weld seams and bolted structures. The cure time for this project was 30 minutes.

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Nashville Fountain Case: In fountain features, it is the chlorine which is almost always the root cause of system failures and maintenance regimes.

A Nashville, Tennessee business park fountain had been built 20 years ago and its rubberized lining was failing badly to the point of causing substantial leakage directly into the ground, requiring frequent top ups. Using Ecodur provided a tough, permanent non-toxic seal that could, if necessary, be repaired at any point in the future.

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Wyoming Facility Case: A new water treatment facility in Wyoming will treat up to one million gallons of water a day that comes from oil and gas production in the region. It is the third largest of it kind in the world and it will make water more acceptable for an end-use, whether it be for residential, industrial, or commercial customers.

The facility is located between Casper and Riverton, and it needed a highly stable, non-toxic, robust and waterproof coating for its new concrete water channels which will be exposed to a potentially corrosive array of chemicals in produced water. In addition, operators did not want any downtime, which was achieved by using Ecodur 201S.

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Castagra Awards

Texas A&M – Soil to Oil Program

"Over the course of the last year our research and testing of the product line Ecodur 201 has revealed that this product line is not just a better version of the current comparable systems, but in fact this product is inherently different in nature and is what we truly believe to be a generational leap forward in zero VOC, environmentally friendly coating and insulation technology." Jeremy McNabb, Owner Kymax Coatings Ltd.

Tank Coating Applicator Testimonial

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Rim Operating Testimonial

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Fisher Testimonial

To request additional oil & gas and water & wastewater case studies from our library, please contact us at info@castagra.com