efusion logo

epoxy coated
steel tanks

Balmoral Tanks’ efusion epoxy coated tanks represent the very latest developments in steel tank coating technology. This, in turn, has provided significant engineering and cost benefits to users across a range of applications since the early 2000s.

Epoxy coated steel tanks

efusion® is the brand name for Balmoral Tanks’ in-house steel panel epoxy coating. This fusion bonded epoxy treatment provides a highly resistant coating to the tank panels.

The benefits of epoxy coated steel tanks against more traditional tank coatings include higher durability to impact, lower cost manufacturing, lower carbon footprint and more efficient design principles.

efusion is tested to similar stringent standards as glass coated steel and meets or exceeds the following internationally comparable coating requirements:

ISO 12944
WIS 4-25-01
ISO 28765:2008
EEA 7.20
EEA 7.24
EEA 7.25
AWWA D103-09
WRAS
Balmoral epoxy coated tanks accreditation
Balmoral efusion epoxy coated tanks

Applications

Application efusion efusionHP Stainless steel 316L Stainless steel 304L
Agricultural waste/slurry - -
Potable/drinking water - -
Covered municipal waste - -
Open topped municipal waste - -
Municipal/industrial aeration - -
Municipal/industrial settlement - -
Municipal/industrial clarification - -
Digester liquid zone - -
Digester gaseous zone - -
Leachate storage - -
Borehole/brackish/seawater - -
Desalinated water - -
Demineralised water - -
Treated water - -
UF water - -
Balmoral efusion epoxy coated tanks

efusionHP tanks

Balmoral efusionHP epoxy coated steel tanks are used in the most demanding and aggressive applications and are suitable for specialised coated steel tank applications such as anaerobic digester tank gas spaces. efusionHP is also very well suited to operating in high temperature environments.

Tested to 1500V, the efusionHP coating delivers the highest level of durability and performance available in the storage tank market.

Balmoral efusion epoxy coated tanks

Stainless steel tanks

In addition to fusion bonded epoxy coated steel tanks, Balmoral offers a full range of stainless steel tanks, roofs and ancillaries for use in the water and wastewater industry.

These tanks are available as a complete tank kit in grade 304 and 316 stainless steel, in a combination of grades or as a hybrid tank with fusion bonded epoxy coated steel in the lower rings and stainless steel in the upper rings.

Balmoral efusion epoxy coated tanks

Agfusion tanks

Balmoral’s Agfusion epoxy coated steel storage tanks deliver cost effective performance to the agricultural and slurry storage market. Manufactured and coated at the company’s dedicated powder coating facility Balmoral’s proprietary epoxy coating system delivers a highly durable tank offering many years of virtually maintenance-free service.

Balmoral efusion epoxy coated tanks

Hybrid tanks

As Balmoral offers a range of different tank materials it allows the company to design and engineer tanks with multiple grades of material for different areas of the tank.

By offering a combination of fusion bonded epoxy coated steel grades, efusion and efusionHP, or a combination of materials, efusion and stainless steel, this allows the most cost effective combination of materials to meet storage requirements based on the process design.

Depending on the effluent’s chemical composition, stored temperature and operating conditions, some tank systems will be more aggressive in the liquid to gas/air interface and having a hybrid option deals with this in the most technically robust and budget-conscious way.

Design life

Balmoral epoxy coated tanks, Kowloon Hong Kong

With value engineering at the heart of material selection, Balmoral Tanks’ efusion coating meets all necessary design life expectations. Key factors in achieving optimum product performance begin with the design and manufacturing process, running right through to installation. Retaining in-house control and quality in each of those critical areas is vital in ensuring consistent high levels of performance of any coated steel tank.

Balmoral’s efusion system, and its inherent performance properties, ensures the end user receives the best design life expectancy available. The company’s quality assurance standards and installation experience delivers a robust product that is more than capable of design life performance.

The fusion bonded epoxy coating process

Epoxy coating process
Epoxy coating process
Epoxy coating process
Epoxy coating process
Epoxy coating process
Epoxy coating process
Epoxy coating process
Epoxy coating process
Epoxy coating process
Epoxy coating process
Epoxy coating process
Epoxy coating process
Epoxy coating process
Epoxy coating process

Operating from a purpose built state of the art manufacturing plant with over 5,300m2 of internal floor space, the company utilises both CNC punch and laser cutting equipment in its semi-automated production line.

All raw materials are quality checked on arrival before moving into the production phase. Black steel panels are lasered or punched, depending on their thickness, prior to being steel grit shot-blasted to SA2.5/SSPC10 near white finish. After shot-blasting the sheets are automatically transferred to the paint line via vertical rollers if necessary. At point of transfer the panels are automatically weighed as a final quality check on material thickness before being coated.

Following the coating process, the panels undergo three separate quality checks to confirm the external panel colour (spectrometer) internal coating thickness (micrometer) and internal coating integrity (high voltage holiday test). Balmoral operates a zero defect policy with every defective panel being rejected.

Once the final inspection has taken place the finished sheets are packed onto heat treated pallets for transportation.

During panel production, tank components, including nuts, bolts, washers, sealants, etc, are packaged according to the bill of material, whilst fabricated items are procured, produced, quality checked and palletised for transport.

The company is accredited to ISO9001-2015 and enforces quality checks and stop points throughout the production process to ensure goods are procured, received, produced and shipped ‘Right First Time’.

efusion coating performance and quality standards

Internal coating: Thermoset resin fusion bonded epoxy*

Application Test Result Colour
Dry film thickness Elcometer 456 Every panel = minimum of 7/15mils / minimum of 180/400um ral5015
PH range - *PH 2-12 ral5015
Corrosion resistance (Acetic salt spray test) ISO 9227 0mm creep from scribe at 1000hrs ral5015
Hot water immersion 90 days, 75°C CSA Z245.20-14 Meets/exceeds industry standard ral5015
Humidity EN ISO 6270-2 Meets/exceeds industry standard ral5015
Adhesion ISO 21809-2 0mm ral5015
Hardness Buchholz hardness test Indentation resistance = 91 ral5015
Impact resistance ASTM G14 3.2mm (⅛ in) steel plate >18J ral5015
Abrasion resistance Abrasion wheel ASTM 4060 CS17,1000g, 1000 cycles < 26.5mg ral5015
Chemical immersion 50% NaOH, 50% H2SO4 Meets/exceeds industry standard ral5015
Holiday test 1100v/1500v every panel* 100% defect free at test voltage ral5015

* Subject to grade

External coating: Ultra durable polyester*

Application Test Result Colour
Dry film thickness Elcometer 456 6/9mils / 150um-230um ral5013 and 6016
Corrosion resistance (Acetic salt spray test) ISO 9227 16mm2 creep from scribe at 1000 Hrs ral5013 and 6016
Humidity EN ISO 6270-2 1000Hrs - No blistering ral5013 and 6016
Adhesion ISO 21809-2 0mm ral5013 and 6016
Hardness Buchholz hardness test Indentation resistance = 80 ral5013 and 6016
Impact resistance EN ISO 6270-2/ASTM D2794 2.5Nm/22 inch-pound (no sign of detachment) ral5013 and 6016
Weathering EN ISO 16474-2 1000hrs, residual gloss ≥90%, Colour change ∆E ≤50% according to Qualicoat requirements (appendix A7) ral5013 and 6016
Weathering EN ISO 16474-3 600Hrs, residual gloss ≥ 50% ral5013 and 6016

* Subject to grade

Tank installation

Balmoral operates via a network of distributors worldwide that are trained in all areas of tank construction. Experienced Balmoral service engineers are available if additional support is required.

There are two main methods of building modular tanks:

Tank installation scaffolding

Scaffolding

Scaffold building suits open top tanks and tanks in areas of the world where the importation of jacks is difficult or restricted by customs laws.

Tank installation jacking

Jacking

Jack building suits tanks with covers, tall tanks, and project sites where working at height is restricted or perilous. The jacks are normally shipped with the tank kit and allow for the majority of works to be completed within 2.4m of ground level.

Foundations

With value engineering at the heart of material selection, Balmoral Tanks’ efusion coating meets all necessary design life expectations. Key factors in achieving optimum product performance begin with the design and manufacturing process, running right through to installation. Retaining in-house control and quality in each of those critical areas is vital in ensuring consistent high levels of performance of any coated steel tank.

Balmoral’s efusion system, and its inherent performance properties, ensures the end user receives the best design life expectancy available. The company’s quality assurance standards and installation experience delivers a robust product that is more than capable of design life performance.

Note: Bases may vary to suit individual site requirements.

Rebate foundation
Floor kit foundation
Flat base foundation
Embedded starter ring foundation

Case studies

Agricultural biogas plant - Brålanda, Sweden
Agricultural biogas plant - Brålanda, Sweden
1Specification
Application Agricultural biogas plant
Tank type efusion™ epoxy coated steel tank
Dimensions 2 no. Ø17.94 x 8.46m efusion storage tanks with PVC double membrane roof
Fusion bonded steel tank kit - pH 2-11
Scope of work
Design, manufacture and install
2Overview
Nestlé processing plant, Malaysia
Nestlé processing plant, Malaysia
1Specification
Application Potable water storage
Tank type Epoxy coated steel tanks with roofing
Dimensions 1off Ø9.4m x 18m high; 1off Ø14m x 18m high
Capacity Two tanks with total capacity of 3650m3
Scope of work
Design, supply, deliver
Installer Locally provided
2Overview

Enquiries

-

Additional information (if known)

Please give an indication of required tank capacity
Is your tank installation to be located indoors or outdoors?
Please provide foundation type/information, if known
Please provide accessibility distances around the proposed tank location

View Balmoral Tanks terms and conditions of use.

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