Dow Chemical Processing Facility
Large-Scale Industrial Chemical-Resistant Coating Project | Houston, TX
Project Overview
Dow Chemical's Houston petrochemical processing facility required comprehensive industrial coating replacement across 850,000 square feet of processing units, storage areas, and equipment. The facility produces specialty chemicals with extreme corrosive environments requiring specialized chemical-resistant coating systems capable of withstanding continuous exposure to acids, bases, solvents, and elevated temperatures.
Challenges
- Extreme chemical exposure environment requiring specialized coatings
- OSHA PSM (Process Safety Management) compliance requirements
- Coordination with plant shutdown schedule
- Hazardous atmosphere requiring confined space entry protocols
- High-temperature resistant coatings for process equipment
- Multi-phase project across different chemical processing units
Our Solutions
- Chemical-resistant epoxy and polyurethane coating systems rated for specific exposures
- Industrial coating specialists with PSM and confined space certifications
- Comprehensive surface preparation including abrasive blasting and chemical cleaning
- High-temperature coating systems rated to 400°F for process equipment
- Real-time safety monitoring and gas detection systems
- Detailed project planning synchronized with plant maintenance schedule
Results
- Zero safety incidents: 114,000 man-hours without OSHA recordable incident
- Schedule performance: Completed within planned shutdown window, enabling on-time startup
- Quality achievement: All coating systems passed chemical immersion testing
- Coating longevity: Systems engineered for 15-20 year service life
- Cost savings: Efficient execution delivered $380,000 under budget
- Recognition: Dow Chemical Contractor Safety Excellence Award
Technical Specifications
Coating Systems by Zone
- Process vessels: Glass-flake epoxy (12-15 mils DFT) for severe acid/base exposure
- Secondary containment: 100% solids novolac epoxy meeting EPA 40 CFR 264/265
- Piping systems: High-temperature epoxy-phenolic (rated to 400°F)
- Structural steel: Multi-coat epoxy/polyurethane system (SSPC SP-10 surface prep)
- Concrete floors: Chemical-resistant epoxy mortar with topcoat
Compliance & Testing
- OSHA 29 CFR 1910.146 (Confined Space Entry)
- OSHA 29 CFR 1910.119 (Process Safety Management)
- NACE SP0178 (Design, Fabrication, and Surface Finish)
- SSPC SP-10 (Near-White Blast Cleaning)
- ASTM D4060 (Abrasion Resistance Testing)
- ASTM C581 (Chemical Resistance Testing)
Client Testimonial
"Moorhouse Coating's industrial expertise was evident throughout this complex project. Their coating specifications were precisely tailored to our chemical exposures, and their execution was flawless. Zero safety incidents across 114,000 man-hours demonstrates their commitment to safety excellence. We completed startup on schedule thanks to their performance."
Need Chemical-Resistant Industrial Coatings?
Our industrial coating specialists have extensive experience with chemical processing, petrochemical, and manufacturing facilities. We understand chemical resistance requirements, safety protocols, and shutdown coordination. Trust us for your next turnaround or maintenance project.