In 2024, a 283-foot-tall deluge tank was constructed at the Virginia Commercial Space Flight Authority’s Wallops Island Flight Facility. A robust protective coating was essential to safeguard the tank’s integrity and appearance against harsh coastal conditions and operational demands.
The tank, which stores approximately 200,000 gallons of water, plays a critical role in launch operations. It releases high volumes of water onto the launch pad during liftoff, helping to dampen sound energy and protects both the infrastructure and the launch vehicle from intense acoustic and thermal forces.
Given its coastal location and mission-critical purpose, the tank required a durable, high-performance coating system to ensure long-term functionality and protection.
Induron Protective Coatings supplied both the interior and exterior coating systems. The company partnered with Pittsburgh Tank & Tower, the tank manufacturer and erector, and Corrosion Control Corporation, which performed the complex coating application.
Interior Coating System
The tank’s interior was lined with two coats of Ruff-Stuff 2100 Coal Tar Ceramic Epoxy Tank Lining, selected for its exceptional durability. Designed to resist abrasion and chemical attack, this lining can withstand flow rates exceeding 30 feet per second when the tank discharges onto the pad.
Exterior Coating System
The multi-layer exterior system was engineered for maximum durability and long-term performance:
Primer
CeramaPrime™ Epoxy Primer was applied directly to prepared carbon steel, providing excellent adhesion and corrosion resistance.
Intermediate Coat
Indurethane™ 6700, a high-solids, low-gloss acrylic polyurethane, served as the base coat for the finish coat, enhancing system performance and consistency.
Finish Coat
Perma-Gloss™ Fluorourethane, formulated with LUMIFLON® FEVE resin technology, was applied as the final layer. This advanced finish delivers exceptional UV resistance, long-term color and gloss retention, and outstanding weatherability — all critical for coastal exposure near the Atlantic Ocean.
The finish coat, applied in a rich wrought iron black, required only a 2-mil thickness thanks to its superior coverage. Four logos were added using Perma-Gloss to ensure consistent color and gloss retention.
Standing more than 283 feet tall, the massive structure was painted on the ground to ensure complete coverage and quality control before installation. Despite high winds that temporarily delayed lifting operations, the tank was successfully installed on April 22, 2024.
This project demonstrates effective collaboration and the use of advanced protective coating technologies — including LUMIFLON-based resins — to meet the demanding conditions of a coastal space launch facility.
Photo Credits: ©Induron Protective Coatings