RomânăAcid-Resistant Protective Coatings for Industrial Structures
Chemical processing plants, battery manufacturing facilities, galvanising operations, and industrial drainage systems are exposed to concentrated mineral and organic acids that destroy unprotected concrete and steel within months. Standard Portland cement has essentially zero resistance to acids - even dilute concentrations below pH 4 cause rapid surface dissolution. Gemite's geopolymer coatings and acid-resistant cementitious systems are engineered to withstand the specific acid environments encountered in industrial chemical processing - confirmed by substance-specific chemical resistance testing.
Acid & Corrosion Protection Applications
Chemical Plant Structures
In chemical manufacturing environments, floors, walls, drainage channels, and bund areas are exposed to process chemical spills, condensation of acid vapours, and direct contact with concentrated reagents during maintenance operations. The key failure mode in unprotected concrete is acid attack - acids react with calcium hydroxide and calcium silicate hydrates in Portland cement to form soluble calcium salts, dissolving the binder and leaving a weak, permeable residue. Gemite's acid-resistant systems use geopolymer binders that are inherently resistant to acid attack, providing protection where cementitious systems fail.
Battery Rooms & Plating Facilities
Battery rooms contain sulphuric acid electrolyte that escapes during charging (as aerosol) and through spills. Plating facilities use hydrochloric and sulphuric acid solutions at elevated concentrations. Both environments require coatings with confirmed resistance to the specific acid type, concentration, and temperature - and must also resist electrical conductivity requirements in battery room applications. Gemite specifies anti-static or electrically isolating variants where required by the facility's electrical safety design.
Key Performance Characteristics
Geopolymer Acid Resistance
Gemite's geopolymer systems resist concentrated mineral acids (including H₂SO₄ up to 40%, HCl up to 30%) at service temperatures up to 80°C - outperforming standard epoxy coatings in high-temperature acid environments.
Substance-Specific Testing
Before specifying any anti-acid coating, Gemite confirms resistance against the client's specific chemical list - concentration, temperature, and exposure duration - not generic acid resistance claims.
Bund & Containment Design
Secondary containment bunds are specified to withstand the worst-case chemical exposure from the primary containment - including hot concentrated acid spill scenarios - with appropriate capacity and lining specification.
Drainage Channel Systems
Acid-resistant drainage channel linings prevent attack from continuous chemical flow - including proprietary channel lining systems compatible with Gemite's bund and floor coatings for integrated containment design.
Acid & Corrosion Protection - Technical Questions
What acids can Gemite coatings resist?
Gemite's geopolymer coating range provides resistance to a wide range of mineral and organic acids at various concentrations. General guidance: sulphuric acid up to 40%, hydrochloric acid up to 30%, nitric acid up to 10%, phosphoric acid up to 85%, acetic acid, citric acid, and most organic acids at ambient temperature. Resistance decreases at elevated concentrations and temperatures. Oxidising acids (concentrated nitric acid, chromic acid) require specific system selection. Before specifying, Gemite provides a written chemical resistance confirmation for the client's specific chemical exposure list. Generic acid resistance claims without substance-specific data should not be relied upon.
How does geopolymer compare to epoxy for acid resistance?
Epoxy coatings offer good resistance to many acids at ambient temperatures, and are suitable for the majority of chemical plant applications. Geopolymer systems outperform epoxy in three specific scenarios: temperatures above 60-80°C (where epoxy softens and loses resistance), strongly alkaline environments (pH > 12, where epoxy performs poorly), and fire resistance requirements. Geopolymers are also significantly more thermally stable and do not emit volatile organic compounds during service. The selection depends on the specific chemical and thermal exposure profile - Gemite's technical team recommends the correct system after reviewing your process conditions.
Can existing acid-attacked concrete be rehabilitated rather than replaced?
In most cases, acid-attacked concrete can be rehabilitated if the structural integrity is maintained - if the acid attack is limited to the surface layer and the reinforcement is not compromised. The procedure involves: (1) removal of all deteriorated concrete by hydrodemolition or scarification to reach sound substrate (typically 10-50mm depth); (2) structural assessment to confirm remaining section is adequate; (3) repair of the section with sulphate-resistant and acid-tolerant repair mortar; (4) application of the anti-acid coating system. If reinforcement corrosion is present, additional rebar treatment is required before repair. Our technical team conducts the full assessment and designs the rehabilitation system.
Protecting Industrial Structures from Acid Attack?
Our specialists conduct a full chemical exposure analysis - substance, concentration, temperature, and contact frequency - and specify the correct anti-acid system with written chemical resistance confirmation.
- Written chemical resistance data for your substances
- System selection - geopolymer vs. polymer-modified cementitious
- Bund and containment lining specification
- Application protocol and quality control
Or contact us: office@gemite.tech · +40 232 273 031