Fuel Tank Full Recoat – RAF Portreath (Jun 2025)

Client: OSI Contracts — Location: RAF Portreath — Sector: Defence

Project Overview

At RAF Portreath, a newly installed fuel tank was already showing early signs of
coating failure—despite being only eight months old. The original coating specification
provided just 50 microns DFT, far below what is required for harsh coastal conditions.
Without intervention, the tank would have faced accelerated corrosion and high
maintenance costs.

Objectives

  • Remove the inadequate coating system and prepare the surface for recoating
  • Apply a durable protective system suitable for aggressive marine and coastal exposure
  • Achieve a significantly increased coating thickness for long-term protection
  • Ensure the tank’s finish met both functional and aesthetic standards

Our Approach

• Mechanical Surface Preparation: Full sanding to remove coating defects and establish a
sound surface profile.
• Application of High-Build Epoxy: Recoating with Interseal 670HS, designed for heavy-
duty corrosion protection.
• UV-Resistant Finish: Applying Interthane 990 Jet Black topcoat for gloss retention and
weather resistance.
• Enhanced Thickness: Achieving 350+ microns DFT, more than seven times the original
specification.
• Additional Measures: Removing the access door for powder coating at HQ to maximise
durability and provide a uniform finish.

.

Results

• Long-Term Protection: The new coating system provides reliable defence against
corrosion in a demanding coastal environment.
• Cost Savings: Improved durability reduces the need for early maintenance or costly
rework.
• Professional Finish: The Jet Black topcoat delivers both durability and a high-quality
aesthetic in line with RAF standards.

• Asset Reliability: The tank now has the level of protection it should have had from the
start, safeguarding performance for years to come.