TARKETT – Full Scale Refurbishment
Full Scale Cooling Tower Refurbishment With GRP Lining and Stainless Steel Distribution
Tarkett, a global flooring business with 12,500 employees across 34 locations, needed urgent refurbishment of two severely corroded Carter cooling towers at their Maidstone site. Vistech delivered a complete GRP lining, external coating, and stainless steel distribution replacement within a tight 3-week Christmas shutdown window.
The Challenge
Tarkett’s existing Carter cooling towers were in very poor condition. The mild steel casings were heavily corroded with open holes where the metal had rusted through – a significant health and safety risk, as corrosion encourages the growth of harmful bacteria including Legionella (HSG 274 Pt 1).
The mild steel trough and gutter distribution system on one tower had corroded extensively, creating a bacterial breeding ground. Fan casings and supporting steel structures were also heavily corroded. If left unaddressed, the towers would have become inoperable.
The refurbishment had to be completed within a 3-week Christmas shutdown window, with both towers operational before the site reopened. Weather conditions in winter also presented challenges for GRP lining application, which requires controlled temperatures.
The Solution
Vistech delivered a comprehensive 5-stage GRP lining solution for both cooling towers, creating a tank-within-a-tank with its own inherent structure covering all existing corrosion and leaks. The lining carries a 10-year warranty.
Tower 1 received a full external GRP lining given its severe corrosion, while Tower 2 received an external polyurethane coating. Both towers had their fan scrolls coated. Tower 2’s corroded mild steel distribution system was fully replaced with a new stainless steel trough and gutter system, eliminating the bacterial risk.
To overcome the cold winter conditions, the towers were covered and heated internally using space heaters to ensure successful GRP application. During strip-out, the team discovered that one tower’s top sill was so corroded it required replacement — Vistech designed, manufactured and installed a stainless steel replacement within the same project window, ensuring both towers were fully operational before the works reopened.
Scope of Works
Internal GRP Lining
5-stage GRP tank lining applied to all internal surfaces of both cooling towers, including accessible areas of fan scrolls, with 10-year warranty.
External Protection
External GRP lining to Tower 1 (severely corroded) and polyurethane coating to Tower 2, plus coating to both fan scrolls.
Distribution Replacement
Full replacement of corroded mild steel trough and gutter distribution system in Tower 2 with new stainless steel system including distribution tubes and covers.
Structural Repair
Design, manufacture and installation of stainless steel replacement top sill discovered during strip-out to be critically corroded.
Scaffolding & Access
Erection and removal of perimeter scaffolding for safe access throughout the project.
Programme
Phase 1
Site inductions, permits to work, erect perimeter scaffolding.
Phase 2
Pre-chlorinate and drain both towers. Mechanical and electrical isolation. Strip out internals and fix stainless steel plates on suspect areas.
Phase 3
Internal GRP lining, external GRP lining and coatings, new stainless steel distribution system installation, refit internals.
Phase 4
Post-chlorinate both towers and return to service. Remove scaffolding and leave site clean.
“A great job executed professionally under strict time constraints, in challenging weather conditions.”
— T. Guy, Engineering Manager, Tarkett