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Cooling Water Cycle Corrosion / Erosion Protection and Repair Systems

plastocor-international SA supplies one-stop turnkey, made-to-measure protective coating solutions for common corrosion and erosion problems along the entire cooling water cycle.

PF390 | Place de la Gare 3,

plastocor-international SA supplies one-stop turnkey, made-to-measure protective coating solutions for common corrosion and erosion problems along the entire cooling water cycle.

The company is a world leader in the protection and repair of the entire cooling water cycle. We are experts in supplying pioneer, one-stop turnkey solutions across the entire power generation, petrochemical and utility industry, including wind towers.

Epoxy cladding solutions for long-term power plant protection

Since 1956, plastocor-international SA is proud that our original epoxy plastocor® Cladding System P2000 continues to provide long-term protection of new and old or refurbished tube sheets against galvanic corrosion and erosion and repair of corroded tube sheets.

With more than 60 years of combined experience and know-how, our smart, simple, sustainable solutions repair and protect heat exchangers and condensers, allowing plant operators to make huge savings while also protecting the environment. Increased reliability, productivity and lifespan extension of equipment, plus reduced heavy metal discharge, are just some of the benefits you can expect from our high-quality products and services.

All plastocor® materials are free from volatile organic compounds (VOC), 100% solid and solvent free.

Cladding systems for the optimisation of condenser tube sheets

The company’s epoxy Cladding System P2000 features a thick film coating used for protecting tube sheets against galvanic corrosion and erosion, and for the repair of corroded tube sheets. It can extend the lifespan of tube sheets for more than 25 years and has been successfully applied on thousands of tube sheets in thousands of power generation units around the world.

When tubes are rolled into a tube sheet of dissimilar metal, a galvanic element is formed resulting in severe pit corrosion around the tubes. This leads to weakened tube sheet joints with the risk of leakage and costly shutdown times. The plastocor® Cladding System helps prevent and repair damage to the condenser tube sheet, tube-to-tube-sheet joints, tube ends and along the entire tube length.

Our cladding system entails an ultra-durable protective cladding of almost all metal types of tube sheets, completely covering the tube sheet and encapsulating the tube ends into a 100% solids epoxy cladding of 3mm-5mm thickness. Adding strength and integrity to the tube-to-tube-sheet joint, the system generates leak-tight joint protection with the risk of galvanic corrosion being drastically reduced to a minimum.

Inlet solutions for galvanic corrosion / step-erosion protection

The original plastocor® Tube End Inlet Coating System P400-IL offers plant operators a cost-efficient and time-saving option when it comes to decisions on retubing and shutdowns, which are both costly undertakings. One of the most common problems found in condenser and heat exchanger tubes is that of tube inlet and outlet corrosion and erosion, resulting in a shorter lifetime for these tubes. Our sophisticated system can indefinitely protect and repair these tubes while offering the optimal life extension of more than 20 years and it does so at a fraction of the costs involved in retubing.

The tube-end inlet system, applicable to both tube inlet and outlet, creates a feathered termination, eliminating the chance of step-erosion, which is another common problem when using plastic or metal inserts. The plastocor® Inlet System with its three-step method can actually bridge small perforations of the tube wall, repairing the tube and returning it to service, postponing, or indeed eliminating the need to retube.

In combination with plastocor® tube sheet cladding, our inlet system creates a uniform and smooth transition from water box to tube interior, eliminating galvanic corrosion and tube-to-tube-sheet-joint leakages. This reduces fouling and turbulence, raising flow efficiencies, while still permitting the unrestricted use of eddy current testing and most tube cleaning methods.

Thanks to its three-step method, the plastocor® Tube End Inlet Coating System allows for expert planning and optimisation of budgets.

Tube lining systems for full-length tube protection

The original patented plastocor® tube lining system is an attractive alternative to prolong the lifespan of condensers and heat exchangers. The heat transfer rate, as well as the integrity of condenser and heat exchanger tubes, will deteriorate over time due to fouling, corrosion and/or erosion. When tube damage considerably reduces the efficiency of the condenser or unit, retubing becomes a highly time consuming and costly operation.

Our unique on-site application system enables full-length tube coatings of approximately 15m in length and can be carried out during regular outages to extend the lifespan of small calibre tubes (3-4mm) of condensers and heat exchangers damaged by erosion and corrosion. It also improves the efficiency of condensers and coolers by reducing fouling and recuperating already lost tubes due to erosion.

Tube lining eliminates almost all metal ion discharges to the cooling water such as copper, zinc, arsenic, as well as chemical cleaning, resulting in expert tube and environment protection.

plastocor® Technology, in combination with the plastocor® Inlet System, plastocor® Tube Lining System, and plastocor® high-performance coatings for water boxes and other cooling water cycle equipment, is the ultimate protective system for the entire condenser. plastocor® technology systems are designed to endure extreme conditions and can be applied in all climatic conditions.

Please use the enquiry form on this page to contact us.

plastocor® Cladding System

The original epoxy plastocor® Cladding System is a thick film coating used for long-term protection of new tube sheets against galvanic corrosion and erosion, and for the repair of corroded tube sheets.

plastocor® Inlet Coating System

plastocor® Inlet Coating System, applicable to both tube inlet and outlet, creates a feathered termination, which eliminates the chance of step-erosion.

plastocor® Tube Lining System

The original patented plastocor® Tube Lining System is used for the internal protective coating of heat exchanger and condenser tubes along their entire length, prolonging equipment life while also increasing its availability.

plastocor® P400 High-Performance Coating Systems

plastocor® P400 High-Performance Coating Systems are specially developed to endure the extreme conditions of condenser and cooling water cycle equipment and are suitable to apply on various substrates such as carbon steel, cast iron or concrete.

plastocor® DIY Wind Tower Coating Systems

plastocor® DIY Wind Tower Coating Systems are suitable for use on both on and offshore wind towers and are designed to withstand even the harshest environments and weather conditions.

Alcoa Gas-Fired Cogeneration Facility

Alinta's natural-gas-fired cogeneration facility is located in Alcoa's Pinjarra Alumina Refinery in Western Australia. The A$300m facility was built in two stages.

Lippendorf Power Plant

The Lippendorf power plant in Germany has been modernized and slightly expanded, and is now producing 16,000MW of electr

Civaux 1-2

France has carried out its nuclear power programme with single-minded determination.

plastocor® – A Track Record that Speaks for Itself.

Over the last number of months, we have embarked upon a journey to showcase to the world how a breakthrough invention some 65 years ago continues to impact the world of condenser corrosion and erosion protection and repair.

4 October 2021

plastocor® Breakthrough Invention Still Blazing a Trail in Tube Sheet Protection

While today plastocor-international SA celebrates over 65 years in the corrosion prevention and repair field and is recognised as a global leader in pioneering solutions in that field, way back in 1956 few may have guessed that the invention of the original plastocor® Cladding System would have set in motion such an important breakthrough in tube sheet protection.

10 May 2021

plastocor® Delivers Donated Masks to Non-Profit Organisations

plastocor®, provider of smart, simple, sustainable solutions for corrosion and erosion problems in the cooling water system, has extended its sustainable solution to working in confined spaces during Covid-19 to wider society.

11 September 2020

plastocor® Launches Masks4Good Initiative

Living and doing business with Covid-19 is becoming a reality across many countries these days as some economies cautiously reopen and make their first attempts to resume economic activity.

1 June 2020

plastocor® INLET System Provides Sustainable Long-Term Solutions

While many power plants will be looking at how to secure energy supply and maintain efficiency during the current global crisis, at plastocor-international SA, we continue to offer state-of-the-art technology solutions that allow power plants optimise performance and achieve reliable output.

28 April 2020

plastocor® and Teflon Partner to Provide Solutions for Energy Market

On 12 November, at PowerGen Europe 2019 plastocor-international and The Chemours Company announced details of their joint collaboration into tackling the specific problem of biofouling, aimed at further reducing unscheduled downtimes and high maintenance costs for plant operators.

26 November 2019


PF390 | Place de la Gare 3


21, En Chaplerue

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