Muja Power Station – A&B Turbine Boiler House
Rust Conversion | Corrosion Prevention | Asset Protection | Future Proofing
Project Overview
Thermoshield was engaged to restore and protect the boiler house roof of the A&B turbine buildings at Muja Power Station in Collie, WA. The existing roof showed advanced, widespread rust that posed a serious threat of irreparable corrosion and total roof failure.
A full roof replacement was ruled out due to cost, complexity, and safety risks, especially considering the uncertain long-term operation of the power station. Instead, Thermoshield delivered a multi-stage rust conversion and restoration coating system — a highly durable, safe, and cost-effective alternative, backed by a 10-year warranty.
Key Benefits Delivered
Full Restoration Without Roof Replacement
- Prevented the need for total roof replacement
- Saved significant capital investment
- Eliminated safety risks associated with sheet removal and reinstatement
Permanent Rust Conversion Process
- Applied rust-converting etch primer that chemically neutralises corrosion
- Converts unstable oxides into stable, rust-resistant metal phosphate
Five-Coat Protection System
- Rust Converter – penetrates and stabilises rust
- Etch Primer – seals and prepares all surfaces
- Thermoshield Coat 1 – light grey base
- Thermoshield Coat 2 – white contrast layer
- Thermoshield Coat 3 – light grey top seal
- Builds thick, impermeable membrane for maximum UV and environmental protection
High-Pressure Surface Preparation
- Power washed at 3,500 psi to remove coal ash, grime, and loose rust
- Ensured maximum bond strength and coating effectiveness
- Safely completed at height with secured anchor points and spotters
UV & Weather Shield
- Final coating reflects solar radiation
- Protects against water ingress and oxygen penetration
- Stops corrosion at its source
Scope of Works
- Inspection & Diagnosis
- Identified accelerated rust due to water + coal ash contamination from chimney stacks
- Surface Cleaning
- Intensive pressure washing across multiple roof zones (east, west, central)
- Rust Conversion & Etch Priming
- Applied targeted and full-surface primers to convert and seal
- Triple Thermoshield Coating
- Built up protective ceramic membrane using alternating contrasting layers for visibility and coverage assurance
- Final Sealing & Warranty
- Delivered uniform finish across entire boiler house roof
- Issued a 10-year warranty for rust protection and coating performance
Client Outcome
“Thermoshield’s restoration work has safeguarded our turbine boiler house without requiring a costly and dangerous roof replacement. We’ve future-proofed the asset and improved safety for ongoing operations.”
This project demonstrates Thermoshield’s expertise in industrial rust conversion, working at scale in high-risk environments to deliver long-term asset protection with minimum disruption.
Contact Us
Thermoshield Australia Pty Ltd
Factory 11, 42 Mills Road, Dandenong, VIC 3175
Email: gavin@thermoshield.com.au
Phone: 0417 563 955
Website: thermoshield.com.au
