Boiler Coating and Boiler Repair

Extending boiler lifetime up to 3 times

Boilers are large and expensive installations which can suffer enormously from wear caused by corrosion and erosion, aggravated by very high temperatures. The exact type of wear experienced varies from one part of a boiler to another and is influenced by the overall design of the boiler and the type of combustible fuel.

Castolin Eutectic´s protective coatings significantly extend the service life of worn boiler components, making them last longer than uncoated new parts. Our protective coatings are a more cost-effective solution than replacement of the worn parts with new ones and offer direct savings in materials and valuable reductions in downtime. Additionally, Castolin Eutectic offers the widest range of coating products, so protection can be tailored against the specific combination of wear phenomena found in each part of every boiler.


Ask an Expert


Tube Armor prevents slag from depositing on tubes and boilers

Despite their industrial application and heavy-duty appearance, tubes require stringent care and maintenance. This is a result of slag – the fine particulates that build up on tubes to cause corrosion, erosion, leaks and other failures. Too much slag literally chokes a boiler by restricting airflow. Once this happens, the specified air-to-fuel ratio no longer applies, causing fuels to burn improperly. If the fuel in question has high mineral content, you also have the added safety challenges caused by clinker formation.

Tube Armor helps prevent slag from depositing on tubes and boilers with a proprietary spray-on ceramic coating. It is a non-porous, non-reactive shield that resists ash, oxidation, erosion, iron sulfide corrosion, sulfur permeation and hazardous chemical byproducts. Tube Armor is applied on the prepared surface one coat at the time until the recommended thickness is achieved. The convenient spray-on delivery system allows us to cover up to 2000 square meters in a single day.

For more information please download our TubeArmor ™ Brochure All Whertec Boiler Coatings solutions

ChromeClad is applied faster than any other thermal spray system

Thanks to ChromeClad’s advanced composite system, your operation can experience exceptional protection even in the most challenging conditions.
  • Superior bond strength: will not flake, spall or crack
  • ChromeClad thickness is measurable: it is a readable, verifiable coating
  • Erosion resistant surface is impervious to airborne particulates, impermeable to corrosion and resistant to thermal shock
  • Non-catalytic: prevents salt cake and slag build-up

For more information please download our ChromClad Brochure



  • Excellent references
  • We are flexible
  • Wear and corrosion analysis
  • New Materials development


Excellent references

Together with our partners, during the last decades we have proved that preventive maintenance on boilers can extend the lifetime by as much as 2 to 3 times. Such maintenance operations are undertaken every day by our technicians, with 80% of them being on-site repairs and the rest workshop repairs.

Our specialists are highly adaptable experts having worked on a broad range of boiler designs for more than 20 years throughout the world. From Pulverized Fuel fired boilers to fluidized bed boilers, we have also been successful in supplying boiler manufacturers with new OEM parts produced on a regular basis with the unique Castolin Eutectic protective coatings.

We are flexible! Jobs on site or in our facilities

We have general purpose facilities in most countries, equipped with "state-of-the-art" technology, diverse process technologies and highly skilled technical specialists. Depending on your request, the job can be undertaken in our own facilities as well as at your plant. When your boiler components are too large to be moved for example, our Castolin Services maintenance experts will visit your premises to solve the problem on-site.

Flexible processes

Our experts can provide outstanding coating quality using a wide range of processes, from cold spraying, spray and fuse, wire spraying to HVOF. Thanks to our long experience with boiler refurbishment we have developed special equipment installations that addresses the issues of boiler access for on-site coating or full automation for OEM boiler coating work.

Wear and corrosion analysis

The latest state-of-the-art testing machines and facilities are essential to accurately measure and understand the complex relationship between chemistry, process and application.

We work with world experts in Technical Universities for testing and modelling in addition to having fully equipped labs with electron microscopes and wear test facilities.

New Materials development

Providing complete solutions for boiler maintenance and performance improvement is our goal. Thanks to our R&D department and the long experience in maintaining boilers, we have developed special products providing unbeatable wear and corrosion resistance: our NanoAlloys® as well as our range of unique powders and wires developed for boiler coating.



Castolin Eutectic has a powerful weapon in the wire alloys for its war on “High Load High Wear” by using a new approach. The world’s first NanoAlloy™ formulation was developed to provide outstanding abrasion and erosion resistance. This was achieved by using a lower cost ferrous alloy with bulk hardness values reaching 71HRC!

Industry proven Spray and Fuse alloys

Castolin Eutectic was amongst one of the first companies to recognise and offer nickelbased self fluxing alloys as a wear and corrosion resistant coating for boiler tubes in the 1980s and have developed a considerable reputation and experience of these alloys. A novel high Molybdenum, high silicon alloy was developed and patented for severe corrosive environments and patented. This solution combined the inherent properties of such fused coatings such as diffusion bonding, zero through porosity with improved performance over even welded 626 alloys. The increasing demands of waste incineration environments are leading to new developments.

EuTronic® Arc Wires

Through development in the early 1990s with leading power companies and high temperature wear institutes a family of iron-based high temperature boiler coating alloys was developed for arc wire spraying. Today these solid industrial references are being used for new alloy development, spurned by improvements in application equipment and increasing performance demands.


The unique quality and properties of HVOF are attractive to boiler coating. The experience gained in arc wire and powder alloy developments is being modified to bring a new generation of Fe and Ni alloy powders for HVOF spraying.