StackGard™ Coating
High-Temperature StackGard™ Coating for Industrial Stack Corrosion Protection
Product Description
StackGard™ Coating is a two-component, high-temperature corrosion protection system developed for steel chimneys, ducts, and fans operating in severely aggressive flue-gas environments. Designed for industrial facilities in California and similar operating regions, this corrosion-resistant stack coating forms a dense, impervious thermoset barrier that protects steel against chemical attack, abrasion, and thermal stress.
Industrial flue gases generated in cement plants, metal smelters, waste incinerators, power generation facilities, and oil refineries commonly contain SO₃, SO₂, HCl, NOx, and entrained particulates. When combined with moisture and temperature cycling, these gases create highly corrosive conditions that accelerate steel loss. StackGard™ is engineered to maintain adhesion and film integrity under these combined stresses, supporting long-term stack service life in high-temperature operating zones.
Applications
StackGard™ is intended for internal steel surfaces exposed to hot, corrosive flue gases and abrasive particulate flow. Typical applications include:
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Steel chimneys connected to baghouses, electrostatic precipitators, and process ducts in cement plants and waste incineration facilities
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Gas scrubbers, ducts, and induced-draft fans in power generation plants and oil refineries
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Ducts, filters, and scrubbers in copper, zinc, and lead smelters
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Industrial exhaust stacks operating in coastal or marine-adjacent environments require industrial stack corrosion protection in California.
Each installation is evaluated based on operating temperature, gas chemistry, substrate condition, and maintenance access to ensure consistent coating performance.
Benefits Across Industrial Environments
Industrial assets face constant attack from chemicals, heat, and abrasion. At Polylloy Coatings, we design industrial anti-corrosion coating solutions in California that protect critical equipment in cement plants, power generation facilities, smelters, and more. Our coatings keep equipment in service longer, reduce unplanned shutdowns, and help control total operating costs.
Industries we serve include:
Performance
StackGard™ performs reliably in steel areas exposed to hot flue gases at temperatures ranging from ambient conditions up to 255 °C (491 °F). The coating protects against corrosion, abrasion, and mechanical impact while maintaining adhesion under continuous thermal exposure. Its dense thermoset structure resists penetration by acids, salts, and moisture. The coating’s strong bond to steel and tolerance for thermal movement prevent cracking, blistering, and edge lifting commonly observed in conventional high-temperature stack linings. StackGard™ has demonstrated long-term performance on chimneys, ducts, and fans operating in chemically aggressive industrial environments.
Material Composition and Protective Mechanism
StackGard™ derives its durability from a tightly cross-linked thermoset matrix engineered for high-temperature service. Once cured, the coating forms a continuous, low-permeability barrier that limits diffusion of corrosive gases and condensates to the steel substrate.
Chemical bonding to properly prepared steel minimizes under-film corrosion and prevents loss of adhesion during thermal cycling. Protection is achieved through barrier continuity and substrate adhesion rather than excessive film thickness, ensuring dimensional stability and long-term performance.
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Installation
StackGard™ is supplied as a two-component system mixed at a 4:1 volume ratio immediately prior to application. The coating is applied by air or airless spray to clean, dry, sandblasted steel surfaces prepared to the specified standard.
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Initial cure: approximately 12 hours at room temperature
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Inspectable state: dry, tough film suitable for thickness and integrity checks
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Defects or discontinuities may be recoated prior to final cure
**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