Specialist Epoxy Lining & Remedial Works

Epoxy glass flake lining application inside 200m power plant chimney in Malaysia

Case Study

Specialist Epoxy Lining & Remedial Works

Balanced Engineering & Construction (BEC) was engaged to deliver specialist epoxy glass flake lining and remedial works for Chimney (T4) at Tanjung Bin Power Plant, Johor, Malaysia, following the 2025 fire incident affecting the plant’s pollutant removal system.

The scope included the removal of existing borosilicate blocks and the supply and application of Epigen XD005FL epoxy glass flake lining to critical internal flue liner surfaces.

The works were undertaken to restore corrosion protection performance, safeguard structural integrity, and support the continued safe and reliable operation of the power plant’s flue gas system.

Project Challenges

The project required rapid mobilisation and controlled execution within a highly demanding industrial environment:

  • Short Mobilisation Period – Planning and manpower deployment were required within an extremely compressed timeframe.
  • Limited Access Equipment – Only one centrally suspended gondola was available, requiring careful sequencing and productivity management.
  • Aggressive Schedule Requirements – Approximately 3,200 m² of epoxy glass flake lining was required to be applied within a compressed execution window.
  • Confined Internal Working Environment – Coating activities were carried out within the internal chimney space, requiring specialist access methodologies and strict safety controls.

BEC's approach

BEC adopted a structured and specialist execution strategy to deliver the chimney lining works safely and efficiently within the required programme.

Following rapid mobilisation, the team implemented an internal access methodology combining certified abseilers and rope access techniques with a centrally suspended gondola system. The gondola was used as a controlled working platform to support the airless spray equipment and regulated material loading in accordance with Safe Working Load (SWL) requirements.

Removal of existing borosilicate blocks was completed prior to lining application, preparing the flue liner surfaces for the installation of Epigen XD005FL epoxy glass flake lining. Coating application was performed using controlled airless spray systems to achieve uniform thickness and optimal performance.

Approximately 3,200 m² of epoxy glass flake lining was applied within a 14-day single-shift execution window. All works were carried out under BEC’s established safety and quality management systems, ensuring coating integrity, durability, and long-term corrosion protection performance.

The BEC Advantage

Through rapid mobilisation and disciplined execution, BEC reinstated internal corrosion protection across 3,200 m² of flue liner surface, reducing downtime and safeguarding continued operational performance.

Backed by proven epoxy glass flake lining expertise and specialist rope access execution capability, BEC supports asset owners with dependable corrosion protection and remedial solutions in high-risk industrial environments.

Planning remedial chimney lining or corrosion protection works?
Contact BEC to discuss specialist epoxy glass flake lining solutions for power plant and industrial applications.

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Frequently Asked Questions

What is epoxy glass flake lining and where is it used?

Epoxy glass flake lining, such as Epigen XD005FL, is a high-performance protective coating used to guard steel or concrete surfaces against corrosion in aggressive environments, including power plant flue gas systems and chimneys.

Why use rope access and a central gondola for internal chimney coating works?

Rope access allows safe, efficient coating application inside confined chimney structures where traditional scaffolding may be impractical or time-prohibitive.

How quickly can chimney lining works be mobilised?

With specialist teams and integrated planning capability, mobilisation can commence within days, depending on project requirements.
Projects Details:
Owner

Malakoff Corporation Bhd

Client

Turcomp Engineering Services Sdn. Bhd.

Location

Malaysia

Completed

January, 2026