Glass Flake Lining for Steel Pickling Lines

Pickling is a critical step in steel processing. Before steel strip, wire, bar, pipe or tube can be cold rolled, drawn, galvanised or coated, its surface scale must be removed. Most plants do this by passing the steel through hot acid baths, typically hydrochloric acid or sulphuric acid. Integrated steel plants, cold rolling mills, wire drawing units, tube mills, galvanising plants and fastener makers all run pickling operations.

The same acid that removes scale from steel will attack the equipment that holds it. Pickling tanks, rinse tanks, acid storage tanks, fume ducts, scrubbers and floors are constantly exposed to hot acid, fumes and splashes. CHEMIPROTECT supplies glass flake coating and lining systems along with acid-resistant brick, tile and mortar systems to protect pickling lines and keep production running.

The Corrosive Environment of a Pickling Line

Hot mineral acids. Hydrochloric and sulphuric acid baths are often heated to speed up scale removal, making them more aggressive.

Acid fumes. Heated baths release acid vapour that condenses on hoods, ducts, structures and building steel.

Splashing and dripping. Strip and coils carry acid between tanks, wetting floors, walls and supports.

Rinse water. Rinse tanks hold dilute acid that still corrodes unprotected steel and concrete.

Mechanical wear. Coils, wire bundles and handling equipment can strike tank walls and floors.

Temperature cycling. Line stops, starts and bath changes cause thermal stress on linings.

Equipment failure in a pickling line can stop downstream rolling, galvanising or drawing operations. Reliable corrosion protection is therefore central to plant productivity.

How Glass Flake Linings Protect Pickling Equipment

Glass flake linings use a chemical-resistant resin filled with overlapping glass flakes. These flakes block the direct path of acid and moisture, forcing them to travel a long, winding route to the substrate. The barrier effect reduces permeation, which is a common cause of lining failure in hot acid service.

The glass also improves hardness and abrasion resistance, while lowering shrinkage stresses during curing. Glass flake linings can be applied to steel and concrete and repaired locally after damage. In the most severe zones, such as hot pickling tanks with mechanical impact, glass flake linings are often used as a membrane behind acid-resistant brick or tile.

Areas We Protect in Pickling Plants

Area	Exposure	Recommended approach
Pickling tanks	Hot hydrochloric or sulphuric acid, impact	Glass flake membrane with acid-resistant brick or tile lining, depending on severity
Rinse tanks	Dilute acid, water	Glass flake lining
Acid storage and day tanks	Concentrated or spent acid	Chemical-resistant glass flake tank lining
Acid regeneration areas	Acids, fumes, heat	Glass flake coatings on equipment and structures
Fume hoods and ducts	Acid vapour condensation	Glass flake coating inside ducts and hoods
Fume scrubbers	Acid gases and scrubbing liquor	Glass flake lining for scrubber shells
Floors, trenches and sumps	Acid spills and rinse water	Acid-resistant tiles, bricks and mortars over a membrane
Building steel and supports	Acid fumes and splashes	Protective glass flake coating

Combining Glass Flake with Brick and Tile Linings

Hot pickling tanks often face both chemical attack and mechanical damage from coils or wire bundles. In these cases, a layered system works best:

Substrate preparation of the steel or concrete tank.

Glass flake membrane as an impermeable chemical barrier.

Acid-resistant brick or tile lining set in suitable acid-resistant mortar to protect the membrane from heat and impact.

CHEMIPROTECT supplies acid resistant bricks, acid resistant tiles and a range of acid-resistant mortars, including MIPRO-FA and MIPRO-K. Our acid-alkali resistant brick, tile and stone lining service brings these together with glass flake membranes. Mortar choice depends on whether the acid is hydrochloric, sulphuric or mixed, and on temperature, so our team recommends the right combination for each tank.

Glass Flake Products for Pickling Lines

CHEMIPROTECT’s MIPROGLASS range includes MIPROGLASS 101 SV, MIPROGLASS 201 SV, MIPROGLASS 201 E, MIPROGLASS Primer VE and other grades. Each pickling application has its own acid type, concentration and temperature, so product selection should always be confirmed with our technical team. See the full glass flake product range.

Application and Quality Control

Shutdown planning to drain, neutralise and clean tanks and ducts safely.
Removal of failed linings and contaminated material.
Surface preparation, including abrasive blasting of steel and mechanical preparation of concrete.
Repairs to pitted steel or damaged concrete.
Priming and glass flake application in layers to the specified thickness.
Inspection, including thickness measurement and spark testing on steel.
Brick or tile installation where a layered system is specified.
Curing before acid is introduced.

Neutralising and cleaning old pickling equipment is essential, because residual acid and salts in the substrate can cause early lining failure.

Floors and Drains

Acid spills and rinse water make floors, trenches and drains in pickling bays especially vulnerable. Concrete attacked by acid loses strength, and damaged floors become safety hazards. CHEMIPROTECT combines membranes with acid-resistant tiles, bricks and mortars to build durable floors and drains. For more information, read our guides on chemical resistant drainage systems and chemical spill containment systems.

Benefits for Steel Processors

Longer tank and duct life in hot acid service.

Fewer unplanned stoppages of pickling and downstream lines.

Safer working conditions with sound floors and contained acid.

Protection for building structures from acid fumes.

A single supplier for glass flake, brick, tile and mortar systems.

Signs That Pickling Equipment Needs Relining

Plant teams can often spot lining problems before they cause a failure. Common warning signs include:

Rust staining or weeping on the outside of steel tanks.

Blisters, cracks or soft spots in existing linings.

Loose, cracked or missing bricks and tiles, or eroded mortar joints.

Acid seepage under tanks, through floors or into drains.

Corroded hoods, ducts and nearby building steel, showing fume damage.

Acting on these signs during a planned shutdown is far less costly than dealing with a sudden tank failure that releases hot acid and stops production. CHEMIPROTECT can inspect existing pickling equipment, assess lining condition and recommend whether local repair or full relining is the better option.

Frequently Asked Questions

Can glass flake linings handle hot hydrochloric acid?

Suitable glass flake systems are used in hydrochloric acid service. Temperature and concentration determine the right grade, and severe tanks often use brick or tile over the membrane.

Why use brick over a glass flake membrane?

The membrane provides the chemical barrier, while brick or tile protects it from heat, abrasion and impact from coils or wire bundles.

Can fume ducts be lined?

Yes. Glass flake coatings are applied inside ducts and hoods to resist acid condensation.

How should old pickling tanks be prepared?

They must be drained, neutralised, cleaned and dried, and failed linings removed before new lining work starts.

Do you also supply acid-resistant mortars?

Yes. CHEMIPROTECT manufactures a range of acid-resistant mortars for brick and tile linings.

Protect Your Pickling Line

Share details of your pickling acids, temperatures, tank materials and shutdown windows. We will recommend a glass flake and lining system for your plant. Contact CHEMIPROTECT or explore all industries we serve.

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When used with chemical resistant masonry units and the proper membrane MIPRO-VE will protect concrete and steel sub base from chemical attacks and physical abuse. MIPRO-VE is silica filled vinyl ester mortar supplied in two parts .