For many years leading up to 2024, BeaconMedaes, a tank manufacturer supplying products used in medical air compressor products, faced the unique challenge of needing to coat the interior of their receiver tanks. Used primarily in hospitals, these medical air systems have strict standards for corrosion resistance to ensure safety and durability. Through an exploratory period of trying various coating solutions to extend the tanks’ lifespan, the team was not able to find the best coating protection system for their product – that is, until the customer revisited hot-dip galvanizing with an expert in the industry.

The company first experimented with epoxy linings to address the issue. Epoxy offered protection, but the drawbacks quickly became apparent. Hospitals’ strict requirements for air purity and the presence of air quality monitors in their facilities meant that off-gassing from the epoxy became a serious problem. This issue led to a high rejection rate of the tanks, as hydrocarbons released from the epoxy interfered with air quality and monitoring systems. Additionally, the process of sending rejected tanks back to vendors for repairs became a logistical and financial burden.

With the epoxy coating proving unreliable, BeaconMedaes decided it was time to revisit hot-dip galvanizing. The company had experience with galvanizing in the past; however, they struggled with ash particles from the galvanizing process settling inside the tanks, leading to premature corrosion. After years of dealing with the limitations of epoxy, the team decided it was time to find a galvanizing partner willing to tackle the challenges faced previously.

The galvanizer chosen for the challenge understood the specific issues the company faced and worked to ensure the tanks were drained of any galvanizing fluid quickly, minimizing ash residue. They introduced threaded connections on the tanks, a new adaptation that allowed for “thread chasing,” where the galvanizer would clean the tank threads post-galvanizing. This addition was instrumental in preserving tank quality and meeting medical codes for corrosion resistance.

The benefits of returning to galvanizing with the galvanizer chosen for this project were clear. Galvanizing provided a long-lasting, cost-effective solution that outperformed epoxy in both durability and maintenance. Not to mention, these galvanized tanks were going to be able to withstand the hospital environment for decades, far outlasting the systems built around them. In comparison to epoxy, which required frequent replacement and monitoring, galvanizing was a one-time application that extended the life of the tanks significantly and reduced the need for costly maintenance or replacements. This longevity will result in substantial cost savings over time for the customer and minimize disruptions overall.

Moreover, by eliminating the need for large manways—a design modification some galvanizers had suggested to address drainage issues—the galvanizer’s process maintained the tank’s original structure, making it a more aesthetically pleasing and practical solution. This approach not only prevented the customer from incurring additional costs but also maintained the tank’s streamlined design.

The result was a medical air system component that was durable, cost-effective, and tailored to the unique needs of hospitals—ensuring that all hospital staff and patients continue to stay safe and supported as they walk through the doors of the building for years to come.