Scores of companies have tried to solve the problem of shortening life spans for wellhead equipment that withers away with corrosion when tasked with today’s high-horsepower fracking operations. But only one company has cracked the code…
S+S Industries’ FracTuff is a patented coating system that works by absorbing and dissipating the impacts of high-pressure water, acid, and frac sand, instead of trying to harden the steel against them. The result is enhanced durability up to 17x and increased life spans up to 7x for fluid ends, valves, goat heads, flow iron, and other alloy and stainless steel components.
The technology behind FracTuff was developed by researchers at NASA in 2002. Shortly thereafter it was deployed by the U.S. military to protect the leading edge of helicopter blades from harsh conditions in Iraq and Afghanistan. We have reformulated it and secured six different patents for our oil and gas iteration.
In the world of hydraulic fracturing, erosion, corrosion, and corrosion-assisted fatigue cost producers over $1.3 billion every year. FracTuff has the potential to save users millions of dollars in equipment replacement and repair/downtime costs. It’s perfect for protecting fluid ends from fatigue, cracking of the intersecting bore, and packing bore washouts, as well as the failures that plague a variety of other high-pressure internal components.
As a two-part system–a basecoat of epoxy-based primer mechanically adhered to the substrate, and a nano-composite, siloxane-based topcoat that chemically reacts with the basecoat–FracTuff is similar to an elastomer. The coating protects the underlying metal from impacting particles, cavitation, and corrosion from high-pressure water and frac sand during fracking operations.
Here’s what the application process looks like:
We inspect the equipment for scratches, burrs, and other irregularities or damage and remove them via sandblasting.
The part is further cleaned by solvents and vapor or thermal degreased to remove contaminants, and the areas where coating will not be applied are masked.
We then white metal blast the part with aluminum oxide abrasive media before priming it with a base coat of FracTuff Prime.
After 48-72 hours, custom spray equipment applies the top coat–FracTuff Protect–in several layers totaling anywhere from 7mm to 42mm, depending on the application, which then cures for another 72 hours.
After passing a final inspection, the part is FracTuff ready to be put to work.
FracTuff is able to replace the common method of cladding carbon steel pipe with stainless steel as a cost-cutting measure. FracTuff suffers from none of the drawbacks of cladding, such as weak corrosion resistance in marine environments and propensity to collect dirt. FracTuff is also a lower-cost alternative to cladding, delivering even more value to producers.
S+S Industries is a leading name in the plating and coating industry. After more than four decades in business, we’ve established a reputation as the experts who handle even the toughest jobs…the biggest plating and coating company by size, number of employees, and revenue…the name on more approved applicator lists than anybody else.
But most importantly, we’re known as a family business that does things the right way. We give everything we’ve got to see our customers succeed, and we think that’s what keeps them coming back–and telling others about us–year after year.