FlueGard™ Series
High-Temperature FlueGard® Coating for Industrial Flue Corrosion Protection
Product Description
FlueGard® coatings are two-component polymeric alloy systems developed for corrosion protection in the flue-gas sections of industrial plants. Designed for service in temperature ranges from 225°C to 425°C, FlueGard® provides durable protection for carbon steel and stainless-steel surfaces exposed to aggressive, high-temperature exhaust streams. The high-temperature FlueGard® coating system is engineered for demanding industrial and coastal operating environments.
​
Flue gases generated in cement plants, metal smelters, waste incinerators, power generation facilities, and oil refineries typically contain SO₃, SOâ‚‚, HCl, COâ‚‚, NOx, and abrasive particulates. In combination with elevated temperatures and moisture, these conditions create severe corrosion and erosion risks. FlueGard® maintains adhesion and film integrity under these combined stresses, supporting long-term protection of critical flue components.
.jpg)
FlueGard® Coating Systems
(Product Line Overview)
The FlueGard® product line includes multiple high-temperature coating formulations engineered for varying flue-gas temperatures, corrosion mechanisms, and abrasion severity. Product selection is based on operating temperature, gas composition, substrate condition, and expected wear.
FlueGard®-225SQC
Two-Component Sprayable Quick-Cure Coating (Up to 225°C)
FlueGard®-425S
Single-Component Sprayable High-Temperature Coating (Up to 425°C)
FlueGard®-455CHT
Two-Component High-Temperature Ceramic Coating (Up to 455°C)
FlueGard®-225SQC is a two-component, spray-applied coating developed for pollution-control equipment exposed to corrosive flue gases at moderate temperatures. The quick-cure formulation supports efficient application and turnaround in baghouses, electrostatic precipitators, ducts, stacks, and flue gas desulfurization (FGD) systems.
FlueGard®-225SQC is a two-component, spray-applied coating developed for pollution-control equipment exposed to corrosive flue gases at moderate temperatures. The quick-cure formulation supports efficient application and turnaround in baghouses, electrostatic precipitators, ducts, stacks, and flue gas desulfurization (FGD) systems.
FlueGard®-455CHT is a ceramic-reinforced, spray-applied coating engineered for very high-temperature service and severe abrasive conditions. The system provides corrosion protection in flue components exposed to extreme heat, aggressive gas chemistries, and particulate erosion.
Applications
FlueGard® is intended for internal steel surfaces exposed to hot, corrosive flue gases and particulate-laden exhaust. Typical applications include:
-
Baghouses, electrostatic precipitators, and process ducts in cement plants and waste incineration facilities
-
Flue Gas Desulfurization (FGD) scrubbers, ducts, and chimneys in power generation plants and oil refineries
-
Ducts, filters, and stacks in copper, zinc, and lead smelters, as well as battery recycling plants
-
Industrial flue systems requiring industrial flue corrosion protection in California
Each application is evaluated based on operating temperature, gas composition, substrate condition, and maintenance constraints to ensure consistent coating performance.
Benefits Across Industrial Environments
Performance
FlueGard® performs reliably on steel surfaces exposed to hot flue gases at temperatures ranging from ambient conditions up to 225°C in continuous service. The coating resists corrosion, abrasion, and mechanical impact while maintaining adhesion under thermal stress.
A key performance advantage is its resistance to delamination, a common failure mode of conventional high-temperature coatings. FlueGard® forms a strong chemical bond to the substrate and maintains film continuity, even in industrial and marine environments where chemical and salt exposure accelerate coating degradation.
Material Composition and Protective Mechanism
FlueGard® is a 100% solids, polymeric alloy coating that cures into a tough, impervious thermoset matrix. Once cured, the coating forms a continuous barrier that limits diffusion of corrosive gases, moisture, and salts to the steel surface.
Chemical bonding to properly prepared substrates minimizes under-film corrosion and prevents loss of adhesion during thermal cycling. Protection is achieved through barrier integrity and adhesion rather than excessive film thickness, ensuring dimensional stability under high-temperature service.
Installation
FlueGard® is supplied as a two-component, 100% solids system mixed at a 4:1 volume ratio immediately before application. The coating is applied by airless spray or roller to clean, dry, sandblasted steel surfaces prepared to the specified standard.
-
Initial cure: 12–24 hours at room temperature to an elastomeric, inspectable film
-
Inspection: film thickness and surface continuity verification
-
Localized defects may be recoated before final cure
Final Cure
After inspection, the final cure is performed by heating from ambient temperature to 140–180°C (284–356°F) and holding for several hours. This is typically achieved using hot flue gases during process startup, though external heat sources may also be used when required.
Proven Performance
Applied across flue systems, ducts, and exhaust components in multiple heavy-industry sectors, FlueGard® serves as a proven FlueGard industrial corrosion coating in California and comparable operating environments.
Schedule a Corrosion Control Assessment
20 + Years of Performance | 9 Proprietary PAC Technologies | 1,200 + Global Projects
Engage Polylloy Coatings to evaluate operating temperatures, flue-gas chemistry, and system configuration to determine FlueGard® suitability for industrial flue protection applications.
**Important. All information presented in this document is believed to be reliable and represents the best available data. Polylloy Coatings' only warranty is that its products meet the criteria stated here. Typical properties are to be considered as representative of current production, should not be treated as specifications. Users should independently evaluate the suitability of each product for their application. Products may be toxic and require special precautions in handling. Users should obtain detailed information on toxicity, shipping, handling, and storage procedures, and comply with all applicable safety and environmental standards. Polylloy Coatings, Inc.'s only obligations are those in Polylloy Coatings. Terms and Conditions of Sale for this product. In no case will Polylloy Coatings or its distributors be liable for any incidental, indirect, or consequential damage arising from the sale, resale, use, or misuse of the product. Polylloy Coatings reserves the right to make changes, without notification to the buyer, to materials or processes that do not affect the compliance of any relevant specification