Hot surfaces break the normal rules of coating selection. A binder that performs well at ambient temperature may soften, chalk or simply decompose at elevated service temperature, and thermal cycling adds stress that a standard atmospheric system was never designed for. The selection starts from the maximum continuous surface temperature, not from the corrosivity category.
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Power plant flue gas ducts and hot surfaces
Heat-resistant and acid-resistant systems for stacks, ducts and equipment operating above ambient temperature.
CorrosivityC5-I plus elevated temperature
Typical service life10–20 years
Recommended coating system
| Layer | Type & DFT | Product examples |
|---|---|---|
| Below ~120 °C | Zinc-rich epoxy primer + MIO epoxy + PU topcoat | Standard heavy-duty build |
| 120–200 °C | Zinc silicate or heat-resistant epoxy, no PU topcoat | Heat-resistant system |
| 200–400 °C | Silicone-based or specialised heat-resistant coating | Heat-resistant coating |
| Acid condensate zones | Glass-flake or novolac epoxy where temperature allows | Glass-flake / novolac |
Application critical points
- Establish the maximum continuous surface temperature and any thermal cycling first — it decides the binder family, and no topcoat choice can compensate for the wrong one.
- In flue gas systems, acid condensation at the cold end drives the corrosion. The dew point of the gas, not the average temperature, sets the requirement there.
- Above the service temperature limit of polyurethane, a heat-resistant finish must replace it; a PU topcoat will discolor and degrade even if the primer survives.
Related product categories
Related products from the brands used in this scenario
InterH2O 499SBalloxy HB Light2419K ECO SWANInterbond 2340UPCAluminium Paint H.R5402E THERMO SHADAN UNDERCOAT EPCeilcote 140 FlakelineBaltoflake Ecolife
Related brands & products
Articles are compiled by RichTech from publicly available manufacturer materials and field practice, for selection reference only; the latest official technical data sheets (TDS) prevail.
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