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.
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.
• 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.
MAK POLYPLAST SUPERLAY MINERAL FINISH is a five-layer polymeric waterproofing membrane featuring a 160 GSM non-woven polyester mat as its central reinforcement. SBS/APP polymer-modified bitumen is provided on both sides of the reinforcement to deliver high softening point, heat resistance and waterproofing performance.
The membrane incorporates a thermofusible high-molecular HDPE film on one side and UV-resistant mineral granules on the other side. Its polymeric construction provides 60% elongation and high tensile strength to accommodate structural movement and adapt to different contours.
MAK POLYPLAST SUPERLAY ULTRA is a high-performance SBS-modified elastomeric bituminous waterproofing membrane reinforced with a heavy-duty non-woven polyester and additional protective fleece layer.
The membrane features an engineered mineral crystal finish on the upper surface and a heat-activatable thermofusible film on the underside. It is designed to develop a continuous and uniform bond with freshly poured structural concrete, providing resistance against hydrostatic pressure and mechanical stresses.
Special selvedge technology enables secure side-lap welding using torch application or hot-air welding.
MAKFELT is a bitumen-treated hessian-base waterproofing felt conforming to IS 1322-1993. It consists of a continuous hessian sheet uniformly treated with bitumen and finished with mineral powder to prevent sticking between layers and provide additional surface protection.
MAKFELT is designed to be used as part of a built-up bituminous waterproofing system, with bitumen layers applied above and below the felt.
Real-World Applications of Makphalt's High-Performance Solutions
