Stonhard Revitalises 27-Year-Old Water Tank for Frozen Food Producer in Portugal
Application Area: Water Tank
Stonhard Portugal, a national leader in high-performance flooring and lining solutions, has completed a challenging renovation of a 27-year-old water tank in Avis, Portugal. The project involved revitalising the aging structure to meet the clients’ requirements while overcoming significant environmental and logistical challenges.
Problem
Constructed in 1997, the water tank had not been refurbished in almost three decades, leaving it in disrepair. The floor and walls, made of porous and sandy concrete and the brickwork ceiling exhibited substantial deterioration. The client required a durable, long-lasting lining solution to coat and seal the structure, which would also act as a preparatory layer for installing a certified PVC liner suitable for drinking water.
The tank’s dimensions—18.5 meters in length, 7.2 meters in width, and 4.3 metres in height—combined with restricted access through a 7x1-metre opening posed logistical and safety challenges. Working in the tank also posed safety challenges as it was a confined space with limited ventilation, requiring trained professionals to complete the work.
Solution
Stonhard Portugal developed a tailored solution using 480m² of its advanced Stonchem 510 system to restore and safeguard the water tank. This system delivers outstanding chemical and corrosion resistance, waterproofing, durability and strength.
The porous and aged concrete required extensive surface preparation using handheld grinders, as traditional diamond grinding equipment could not access the confined area. Rust marks identified during preparation were treated with a rust converter before primer application. Stonclad GS was utilised to repair any defective concrete. Dust containment systems were implemented to ensure a clean and safe work environment.
Stonhard Portugal conducted air quality assessments to address the risks associated with the confined workspace. Exhaust systems were installed to improve ventilation, while crane systems facilitated material handling and emergency readiness.
Temperature monitoring revealed a 12ºC increase from the surface to the interior of the tank, affecting material handling and curing times. Stonhard adapted the installation process to account for these variations, ensuring optimal product performance.
“Revitalising the water tank was a complex yet rewarding project. It showcased our ability to tackle unique challenges with tailored solutions that meet the highest durability and safety standards” said Joao Vieira, Construction Manager at Stonhard Portugal.
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