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Frequently Asked Questions - Pancrete


Over the past decades, metal cooling towers have become popular. Tower corrosion may occur in as little as 7 years depending upon water treatment and environmental conditions. Severe rusting to the point of distressed metal of the tower basin and support structure results. Corrosion causes water leaks and increases water consumption. Structural integrity of the tower itself is reduced and gradually performance deteriorates. Inevitably, corrosion makes it necessary to replace the equipment prematurely, often at a cost of tens of thousands of dollars and more.

Pancrete XE provides a tough, corrosion-resistant coating that is applied directly to the interior cooling tower metal surfaces. This restores the surfaces so they are strong, smooth and easy to clean.

The normal application thickness of Pancrete XE is ¼ inch. This thickness helps to distribute stress across greater surface areas. After Pancrete XE is properly applied, maintenance personnel can walk across the basin without fear of falling through the corroded metal which may be a problem before the tower has been restored. Greater thicknesses of Pancrete XE can be applied as well.

Yes. Pancrete XE was engineered in our laboratories to resist commonly used corrosive chemicals.

Both Pancrete T-84 and V-4138 meet and exceed NFPA 90A requirements, providing better fire and smoke ratings than required.

Pancrete XE will work on galvanized towers.

No special equipment is needed for application.

There are instructions provided. The most important thing is removing old rust, deposits and oils from the metal surfaces. This may be done by abrasion blasting using a soft abrasive such as sodium bicarbonate, walnut shells, etc. A wire brush may also be used.

Surface preparation is the most time-consuming step. The tower is drained and residual dirt or debris is removed by brushing and hosing down the surfaces. Total tower coating process can be completed in less than a day.