By: Nick Jones, Induron Protective Coatings Sales & Service Representative
When you work in corrosion control long enough, you learn there are jobs that require precision and then there are jobs that demand the best. The recent digester lid project at the Hilliard Fletcher Wastewater Reclamation Facility in Tuscaloosa, Alabama was firmly in that second category.
These weren’t just any structures. Newly built, field-welded, and erected on-site, the digester lids would be exposed to one of the harshest environments out there: wastewater systems loaded with aggressive chemicals, constant moisture, and long-term operational stress. This is exactly where coatings either prove their worth or fail.
For this job, there was no question what we’d bring to the table: Novasafe, our industrial-grade Novolac epoxy liner and, in my opinion, one of the biggest guns in corrosion resistance.
Starting with the Right Foundation
Performance always starts with preparation. For both the interior and exterior of the digester lids, we specified an SSPC-SP 10 Near White Metal Blast. That level of surface prep ensures we’re working with clean steel, free of contaminants, and ready to form a strong mechanical bond with the coating system.
From there, we built the system the right way:
- Primer Coat: PE-70 applied at 3–5 dry mils
- Stripe Coat: Targeted application of PE-70 on all seams, welds, voids, and sharp edges
- Second Coat of PE-70: Another 3–5 dry mils for added build and uniformity
This process was repeated on both the interior and exterior, ensuring full system consistency across the entire structure.
Bringing in the Big Gun: Novasafe
Once the base system was in place, it was time for the real workhorse. On the interior of the lids, we applied Novasafe, our ceramic-reinforced Novolac epoxy, at 30–35 mils DFT. That brought the total interior system to at least 40 mils dry film thickness—a robust barrier designed to stand up to extreme chemical exposure over the long haul.
Novasafe isn’t just another lining. It’s engineered specifically for wastewater environments where standard epoxies won’t last. Its resistance to chemical attack, combined with its reinforced structure, gives operators confidence that these assets are protected well beyond the short term.
Simply put, when the environment gets aggressive, Novasafe is the can you reach for.
Locking It in on the Exterior
While the interior takes the brunt of chemical exposure, the exterior still needs durable protection against weathering and environmental wear.
For that, we finished the exterior with Indurathane 6600, applied at 2–3 mils DFT, bringing the total exterior system to 12 mils. This topcoat delivers long-term durability, color retention, and an added layer of defense against the elements.
The Result: A Month Well Spent
From start to finish, the applicator completed the entire project in just over a month—a solid turnaround for a system of this complexity and scale. More importantly, it was done right. At the end of the day, projects like this aren’t about how fast you finish but how long they will last.
Wastewater infrastructure is critical, and failure isn’t an option. The right coating system doesn’t just protect steel and concrete but also operations, budgets, and long-term performance.
That’s why, when I’m on-site helping specify a system for environments like this, I don’t hesitate. Novasafe is built for it. And in Tuscaloosa, it delivered exactly what we needed: a tough, reliable barrier ready to take on whatever that corrosive environment throws its way.