KilnGard™ Coating - High-Temperature Corrosion Protection System
Product Description
KilnGard™ is a two-component Polymer–Alloy–Ceramic (PAC) coating system engineered for high-temperature corrosion protection in California and worldwide for kiln shells operating in extreme industrial environments. Designed to perform where refractory meets steel, KilnGard™ prevents chemical attack, abrasion, and thermal distortion, extending the service life of assets exposed to aggressive gases.
The flue gases inside cement and lime kilns are highly corrosive and abrasive, a condition intensified by the increased use of alternative fuels. KilnGard™ has demonstrated exceptional performance on steel surfaces exposed to these severe conditions, maintaining adhesion and structural integrity even under repeated heating cycles.
Field-proven across cement and industrial facilities in California and worldwide, KilnGard™ represents over two decades of development in polymer-alloy-ceramic corrosion technology, protecting critical assets and minimizing unplanned downtime.
Applications
The primary areas of this kilnshell corrosion protection coating in California and global operations include:
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Rotating kilns in cement and lime manufacturing—applied beneath refractory linings on kiln shells.
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Industrial furnaces in waste-to-energy and incineration plants are exposed to corrosive combustion gases.
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Ducts, filters, and stacks in non-ferrous smelters processing copper, zinc, or lead, where acidic flue gases cause rapid metal loss.
These installations operate under sustained heat and corrosive gas flow. KilnGard™ maintains bond strength and resistance to flue-gas attack, ensuring stable protection in the most demanding operating zones.
Benefits Across Industries
Cement & Lime Production
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Kiln shell coating for cement plant. Shells from chloride and sulfur attack beneath refractory linings.
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Reduces shell deformation and refractory failure caused by under-deposit corrosion.
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Extends inspection intervals and lowers maintenance downtime.
Power Generation & Metal Processing
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Protects boiler ducts, filters, and heat-recovery systems from acidic condensates and high-temperature corrosion.
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Withstands mechanical wear from dust-laden gases and thermal shock cycles.
Recycling & Waste Incineration
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Industrial anti-corrosion coating for kilns that resists chemical degradation from mixed-fuel emissions.
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Maintains coating stability and adhesion during high-temperature start-up and shutdown cycles.
KilnGard™ serves as a reliable industrial anti-corrosion coating for kilns and high-temperature steel surfaces, tailored for long-term performance in varied industrial environments.
Performance
KilnGard™ is formulated to perform in the high-temperature gas zones of cement kilns, smelters, and power plants. It provides:
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Thermal and chemical resistance up to 600 °C (1,112 °F).
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Impervious ceramic matrix that resists salt and chemical corrosion in industrial and marine conditions.
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Strong mechanical adhesion on properly prepared steel surfaces.
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Resistance to abrasion and impact, preserving substrate integrity under refractory or exposed surfaces.
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Long service life in areas prone to condensation, thermal cycling, and aggressive flue gas exposure.
Material Composition and Mechanism
KilnGard™ derives its durability from a hybrid Polymer–Alloy–Ceramic network. The ceramic phase creates a dense, impermeable barrier that blocks chemical ingress, while the alloy and polymer phases provide flexibility and adhesion compatible with the thermal expansion of steel substrates.
This engineered structure minimizes micro-cracking and delamination during temperature fluctuations. The result is a coating system that maintains protection even in the most aggressive, high-temperature process environments found in cement kilns, smelters, and power generation systems.
Installation
KilnGard™ is supplied as a dual-component system. Application can be performed by air spray, roller, or brush on a sandblasted, dry steel surface prepared to the specified standard.
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Initial cure
at room temperature, typically 6–12 hours to touch-dry.
Inspection
film thickness and integrity are verified; minor defects can be recoated.
Final cure
heat-activated at 200 °C (392 °F) for at least one hour—commonly achieved during kiln start-up using process flue gases.
Polylloy Coatings’ field teams have successfully applied KilnGard™ systems across cement and power generation facilities throughout California and globally, following strict surface-prep and inspection procedures to ensure long-term performance.
Proven Track Record
20 + Years of Performance | 9 Proprietary PAC Technologies | 1,200 + Global Projects
Contact Polylloy Coatings to schedule a KilnGard™ performance review or site evaluation for your facility in California or worldwide.
**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.