Long-Term Pipeline Protection for HPCL RBPL Expansion Project

Makphalt Team
December 22, 2025

Overview:

As part of the RBPL Capacity Expansion Project, HPCL undertook the laying of new underground gas pipelines at Barwala, Haryana. Given the critical nature of these pipelines and the high cost of corrosion-related failures, HPCL sought a durable, long- term anti-corrosion protection system. Makphalt was chosen to provide a proven, field-tested solution capable of delivering superior performance under harsh underground conditions.

The Problem:

In earlier HPCL projects, pipelines had suffered leakages and corrosion within just three years of installation.
Investigations revealed that the previously used anti-corrosion systems were inadequate against:
• High soil moisture content leading to continuous exposure to dampness.
• Presence of bacteria and fungi in the soil accelerating metal corrosion.
• Inconsistent application quality, leaving micro-gaps for corrosion initiation.
The challenge was to deliver a robust, long-lasting anti-corrosion protection system that could withstand these environmental conditions and extend pipeline life beyond 20 years.

The Solution:

Makphalt supplied a comprehensive coal tar-based anti-corrosion system comprising:
• Mak Primekote (Primer): A coal tar-based primer that ensured strong adhesion to the pipeline surface and enhanced compatibility with the wrapping tape.
• Mak Polykote (Protective Tape): A 2mm thick coal tar tape with anti-corrosive, anti-fungal, and anti-bacterial properties.

Pipeline surface was cleaned and primed with Mak Primekote.

Mak Polykote tape was applied in double layers using a butane torching system, ensuring uniform adhesion and overlap.

The final system formed a seamless, flexible barrier resistant to soil chemicals, moisture, and microbial attack.

The Impact:

• Enhanced Longevity: The system offers over 20 years of corrosion protection, reducing maintenance and replacement costs.
• Zero Leakage: Eliminated the risk of early corrosion-related failures.
• Improved Reliability: Ensured long-term operational safety of critical underground gas pipelines.
• Client Confidence: HPCL approved and appreciated the performance of Makphalt’s Polykote & Primekote system, recognizing it as a reliable anti-corrosion solution for future pipeline projects.

Products We have used

Mak Crack-O-Fill

MAK CRACK-O-FILL is a single component modified cement based filler material to be used for filling of cracks/ Voids and making covings before waterproofing treatments.

To seal crack up to 5-10 mm wide.
To make coving on all junctions.

Mak Blown Bitumen

Mak Blown bitumen is manufactured from bitumen 60/70 by blowning asphalt. We are providing Blown Asphalt in various grades including BITUMEN 150/5 115/15 105/35 95/25 90/40 90/10 90/15 85/25 85/40 85/25 75/25 hard bitumen or hot liquid in bulk.

Oxidized bitumen can also be used in industrial applications like roofing, flooring, mastics, pipe coatings, electrical applications.

Mak Geotex

MAK GEOTEX is a nonwoven, staple, needle punched, geotextile fabric offering a strong, yet lightweight protection, which will stand up to the rigors of construction activities.

Protection of waterproofing membranes during backfilling.
Protection of waterproofing membrane from damage by other trades, during construction.
Acting as a drainage fabric to shed water from the waterproofing membrane.
Acting as a slip sheet (isolation layer) between the waterproofing membranes and concrete topping.

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