The City of Oradea, Romania, had a serious issue with its aged hot water distribution lines. Traditional insulation technologies such as mineral wool or fiberglass resulted in corrosion beneath insulation (CUI), lowering system performance and raising maintenance costs. The city collaborated with CharCoat and Contego Europe LLC on an innovative trial program to repair the pipes and lower surface temperatures at Thermic Point 316.

The project used CharCoat CTI and CTI-120 to remove CUI, reduce heat loss, and lower surface temperatures, all of which improved efficiency and safety.

Challenges Faced

1. Corrosion Under Insulation (CUI): Traditional insulation systems retain moisture, resulting in pipe corrosion over time.
2. Excessive Heat Loss: The exposed pipes resulted in substantial thermal energy loss, lowering overall efficiency.

The CharCoat Solution

CharCoat proposed a two-coat system featuring CharCoat CTI and CTI-120 to rehabilitate and protect the pipes. This innovative solution offered a lightweight, effective alternative to traditional insulation, addressing heat loss and corrosion simultaneously.

Application Process

1. Surface Preparation:
   • The ELASCO team thoroughly cleaned the pipe surfaces, removing corrosion, rust, dirt, and oils to ensure proper adhesion.
2. Primer Application:
   • CharCoat CTI was mixed at 300RPM for 5 minutes and applied as a primer at 500 microns thickness.
   • The coating was diluted with 40% water for effective application on hot surfaces.
3. Final Coating:
   • After 24 hours, CharCoat CTI-120 was applied at 500 microns thickness, achieving a total 1mm DFT (Dry Film Thickness).
   • Application was performed using a brush to ensure even coverage.

Results

Initial Infrared Measurements (Pre-Coating):

• Surface temperature: 65°C

Infrared Measurements (24 Hours Post-Coating):

• Surface temperature reduced to 46°C – 48°C.

Final Infrared Measurements (21 Days Post-Curing):

• Vertical pipes near walls: 36°C
• Horizontal pipes: 43.4°C

Overall Impact:

• Surface temperature reduction of up to 44%.
• Heat loss is minimized, resulting in improved energy efficiency.
• Complete elimination of CUI, thanks to the protective nature of CharCoat coatings.

Benefits of CharCoat CTI/CTI-120

1. Corrosion Resistance:
   • The coatings eliminate moisture retention, effectively eradicating CUI.
2. Temperature Reduction:
   • Surface temperatures dropped by up to 44%, ensuring safety and reducing thermal energy loss.
3. Lightweight Alternative:
   • Unlike traditional insulation, CharCoat’s 1mm DFT system provides the same or better performance without the bulk or weight.
4. Durability and Longevity:
   • CharCoat CTI/CTI-120 offers a robust solution that withstands harsh environmental conditions.
5. Eco-Friendly Application:
   • The water-based system is safe, non-toxic, and environmentally friendly.

The repair of the City of Oradea’s hot water pipes showcases CharCoat CTI/CTI-120’s transformational potential. The CharCoat system, which addressed both heat loss and corrosion, provided a long-term, maintenance-free solution that increased safety, energy efficiency, and operational dependability.

This project demonstrates how novel coating technologies may tackle long-standing issues, making infrastructure more sustainable and cost-effective.