Problem Case Description:

PT. Smelting Indonesia had a corrosion problem inside the seawater intake area, especially on its beams structures due to old painting and corrosion control systems. Three coat painting system was used as surface protection material to keep the metal structures from getting corroded. Unfortunately, the protection system cannot withstand intensive seawater splash in the area. Because of the old painting and continuous contact with seawater splash/ vapor, the corrosion cannot be prevented.

The problem was observed when there was an annual shut down at the plant. Immediate action has to be taken to stop corrosion at beams structure inside the seawater intake area within the limited time at around six days. A normal corrosion control system by using sandblasting and three coat system would not be possible to deliver.

Proposed Solution:

PT. Mahita Karya Persada Teknik (MKPT) Composite Division proposed to do corrosion control on wharf structure using Rust Grip at around 250 microns DFT plus Rust Grip-E as topcoat at around 150 microns DFT. Rust Grip is specialized to stop corrosion from inside through penetrating and encapsulating technology, while Rust Grip-E would be outer guard material that familiar to the wet areas and protecting the metal from seawater splash and vapor.

The process is started by cleaning all existing surfaces by mechanical and hand tools cleaning, especially for some severely corroded areas. No sandblasting is required, so it safe more time. After all, surface cleaned from loose pieces, then ChlorRid is applied by spray to clean up salt contaminant on the metal. After ChlorRid reaction inside metal pores, rinsing with water by using pressure wash. The first Rust Grip application is applied using a brush to help the material penetrate into the pores of the metal. As finishing, build up Rus Grip-E taken by using roller nap.


The job can be delivered on time at only around six days period. After application, beams’ structure inside seawater intake is rehabilitated and completely protected from corrosion and seawater splash. PT Smelting can start its operation inside seawater intake safely and securely.