Fiberglass Reinforced Plastic (FRP) Linings: Industrial-Grade Protection
Expert Solutions from Moon Fabricating Corporation
Since 1923, Moon Fabricating Corporation has been a single-source provider of custom fabrication solutions in Kokomo, Indiana. Our fiberglass reinforced plastic (FRP) linings represent the pinnacle of corrosion resistance technology, providing industrial facilities with reliable protection against harsh chemicals, abrasive materials, and demanding operational conditions.
By 1970, Moon Fabricating Corporation had emerged as one of the largest applicators of corrosion resistant lining products in the nation, having expanded to include monolithic fiberglass reinforced linings and specialty coatings. Today, we continue that tradition of excellence with our premium FRP lining solutions.
Why Choose Moon’s FRP Linings?
Meet even the most demanding corrosion resistant tank lining requirements with our strong, durable, and flexible FRP linings. Whether you need water tank liners or chemical tank liners, Moon Fabricating Corporation is your go-to source for premier products.
Our fiberglass reinforced plastic linings deliver multiple advantages that protect your equipment and improve operational efficiency:
Superior Corrosion Resistance
Facility leaders understand the importance of storage tank integrity and the potential consequences of tank failures. They also know corrosion can play a major role in many of those failures. To fight back against corrosion effects, tank operators must use every available resource to ensure attrition prevention. One of the best tricks of the trade is to install FRP linings.
Many facility managers opt to line their tanks with fiberglass reinforced plastic (FRP) — a “composite material made up of polymer that is supported with fibers for added strength.” FRP is especially adept at preventing material and structural integrity losses based on its ability to withstand the caustic materials around it. This not only helps combat corrosion but also stress fractures and the other deformations corrosion ultimately causes.
Extended Equipment Life
With proper application, FRP linings can help combat internal corrosion and prevent leaks for as long as 10 to 20 years. Plus, in cases where steel tank bottoms are perforated, FRP liners can “minimize the problem of exterior corrosion by providing enough strength to bridge small perforations.” This is a significant bonus for facility owners as lining tank bottoms with FRP is less costly than replacing tank bottoms altogether. According to the Association for Materials Protection and Performance, properly applied FRP systems can significantly extend asset life in even the most aggressive corrosive environments.
Reduced Maintenance Costs
Without secondary liners, a tank may need repainting or re-sealing at certain intervals. This can be extremely expensive, depending on various factors such as whether a tank is situated on the ground or up in the air. To eliminate or decrease these kinds of costs, install FRP linings so that the interior surface will last longer without expensive maintenance. This can lower staff costs or the cost of outside assistance.
Heat Resistant Properties
While FRP’s inherent strengths can make these linings a great option for combating corrosion, they can also maintain corrosion resistance at elevated temperatures. Heat resistance adds an extra layer of security to tank or pipe integrity in extreme conditions.
Shorter Downtimes
Choosing FRP liners rather than replacing tank bottoms is not only more cost effective but also requires less downtime. Quicker installations put your tanks back into commission sooner, helping to keep your operations up and running.
Lightweight Construction
FRP is strong, durable, and also weighs less than other materials. This makes it easier to handle during installation while still providing exceptional protection against corrosion and abrasion.
Versatile Application
Installers can shape and mold FRP linings to fit a variety of tanks and piping designs. FRP is flexible enough that these linings can meet myriad design specifications and protect tanks and pipes in many different types of configurations, including noncircular shapes.
Moon’s Advanced FRP Technology
Moon Fabricating utilizes state-of-the-art application techniques to provide superior bonding and performance of FRP linings. Our specialized equipment and expertise ensure optimal results for every project:
Our 12-foot diameter by 40-foot deep pressure vessel can accommodate larger components as required. For smaller pieces, we utilize our 2-foot, 6-inch diameter by 30-foot deep vessel and pass the savings along to you. All processes are controlled utilizing state-of-the-art electronic monitoring.
Our superior technology offers several benefits:
- Enhanced bonding between the FRP and substrate material
- Optimized curing that maximizes performance properties
- Precise quality control through electronic monitoring
- Size versatility for both large and small components
Types of FRP Linings We Offer
Moon Fabricating Corporation offers different types of fiberglass reinforced plastic linings for tanks, hoppers, piping, chutes, and other than larger installations like silos. Get a customized FRP lining to match any installation, and keep your physical equipment in better condition.
Our comprehensive range of lining materials includes:
Standard FRP Linings
Our standard FRP linings utilize premium vinyl ester resins reinforced with E-glass fibers. These systems provide excellent resistance to a wide range of chemicals, including acids, caustics, and solvents, making them ideal for most chemical processing applications.
Chemical-Specific FRP Systems
For specialized chemical exposures, we offer formulated FRP systems designed to withstand specific aggressive chemicals:
- Sulfuric acid resistant formulations
- Hydrochloric acid resistant systems
- Caustic service linings
- Oxidizer resistant configurations
Abrasion-Resistant FRP
We furnish FRP designed to meet your toughest abrasion applications, including bins, housings, hoppers, piping, chutes, flumes, silos, mineral slurry, limestone slurry, fly ash, iron fines, coal, ore, sand, and many others. Great for ball mills, wheelabrators, and industrial shot blast cabinets, you can reduce equipment failure and shutdown costs while protecting your capital investment.
Additional Specialized Linings
Materials include: Rubber, Hypalon, Chlorobutyl, Koroseal, PVC, Plastisol, Phenolic, Specialty Coatings, Vinyl Ester, and Fiberglass.
Industries and Applications We Serve
Moon Fabricating serves diverse industries requiring corrosion and abrasion-resistant solutions. Our FRP linings are essential for operations in:
Chemical processing and manufacturing, power generation (including FGD systems), steel manufacturing, mining and minerals processing, corn processing and agricultural industries, surface finishing operations, water and wastewater treatment, automotive manufacturing, and plating and anodizing operations. For additional information on FRP applications across various industries, visit Fiber-Tech Industries’ corrosion resistance resources.
Applications include: tank trucks and trailers, chemical storage tanks, water treatment tanks, plating tanks, agitators, pipe, emission control systems, and flue gas desulfurization systems.
Technical Capabilities
With 60,000 square feet of manufacturing space, cranes with 60,000-pound lifting capability, a 300-ton break press, CNC plasma burning capabilities, automated submerged arc welding, and state-of-the-art AutoCAD design and electronic monitoring systems, Moon Fabricating Corporation has the technical resources to handle FRP lining projects of any scale.
Our specialized equipment includes: 12-foot diameter by 40-foot deep pressure vessel (one of the largest in the Midwest) and a 2-foot, 6-inch diameter by 30-foot deep vessel (for smaller components).
The Moon Fabricating Advantage
When you choose Moon Fabricating Corporation for your FRP lining needs, you benefit from:
Nearly a Century of Experience
Moon Fabricating Corporation is a single-source provider of custom fabrication solutions established in 1923 in Kokomo, Indiana. Founded by Richard Moon, the company initially specialized in custom steel fabrication, construction/erection, and machining services. This extensive history has given us unparalleled expertise in creating superior protective lining solutions.
Industry Credentials
Official applicator for North America’s largest producers of protective linings, including Blair Rubber Co. and Polycorp Ltd. Works with leading protective lining and coating providers including Blome, Carboline, Ceilcote, ITW Devcon, Heresite, and Wisconsin Protective Coatings.
Quality Standards
Projects meet applicable codes and standards with verified engineering specifications. Project Approach: Turnkey solutions from design through installation, providing single-source responsibility.
Established Relationships with Industry Leaders
Moon’s reputation for quality has secured relationships with industry leaders including: Energy: AEP, Duke Energy, Ameren Electric; Chemical: Dow Chemical, Lyondell Chemical, ICL Chemical, Pfizer; Manufacturing: United States Steel, Arcelor Steel, Steel Dynamics, Chrysler; Engineering: URS Advatech, FLSmith, Infilco Degremont, Babcock & Wilcox, Graycor, Fluor, M3 Engineering; Agriculture: Cargill, ADM, Tate & Lyle.
Project Process & Client Experience
- Initial Consultation: Expert project managers with decades of experience collaborate with clients to understand specific requirements
- Engineering & Design: Estimating staff uses state-of-the-art AutoCAD to ensure drawings meet specifications and all applicable codes/standards
- Quality Fabrication: Materials and proven fabricating techniques ensure reliability, durability, and functionality
- Professional Installation: Experienced field teams handle installation with rigorous safety protocols
- Ongoing Support: Service and maintenance options to ensure long-term performance
Our comprehensive field services include on-site assembly, installation, and ongoing maintenance to ensure your FRP lined equipment performs optimally throughout its operational life.
Specialized Expertise
FRP for Acid Storage Solutions
Moon specializes in acid storage systems with FRP linings, critical for the 180 million tons of global sulfuric acid production annually. Our tanks incorporate: Material selection specific to acid concentration and temperature, proper ventilation systems to prevent dangerous gas accumulation, and FRP linings to fight corrosion and improve tank integrity. All our chemical storage systems are designed to meet EPA secondary containment requirements to prevent environmental contamination in the event of a primary containment failure.
FRP for Industrial Applications
Our FRP linings provide exceptional benefits: Prevent material and structural integrity losses in corrosive environments, extend tank life by 10-20 years, bridge small perforations in tank bottoms, heat resistant properties for extreme conditions, lightweight yet durable construction, and versatile application for various tank configurations.
Industry Standards Compliance
Our FRP linings meet the ASTM D5421 standard, which covers installation techniques used for fiberglass reinforced plastic in metal tanks, pipes, and other components. This widely-recognized standard ensures your equipment complies with the latest industry practices for proper installation, inspection, and storage conditions. Our application procedures also follow guidelines established by NACE International (formerly the National Association of Corrosion Engineers), ensuring the highest level of corrosion protection performance.
Maintenance and Ongoing Support
To maintain your FRP lining’s performance, we recommend:
- Regular Inspections: Schedule periodic examinations to identify potential issues before they become problematic.
- Proper Cleaning Protocols: Follow recommended cleaning procedures to avoid damaging the FRP lining.
- Temperature Monitoring: Ensure operations remain within the specified temperature range for your particular FRP lining.
- Chemical Compatibility Verification: Before introducing new chemicals, verify compatibility with your existing lining.
Our commitment to your success doesn’t end with installation. Moon Fabricating’s service and maintenance options ensure long-term performance of your FRP lined equipment.
Get Started with Moon Fabricating Corporation
You can count on us when you want to make your core operations more efficient and preserve your investment in physical assets. Contact our team right away for additional information about our FRP lining services. We look forward to assisting your company by manufacturing industrial-strength linings to meet your specific needs and requirements.
With nearly a century of experience, Moon Fabricating Corporation delivers FRP linings that provide unmatched protection, exceptional durability, and superior performance for your most demanding industrial applications.