In the Republic of Karakalpakstan, the heat and frost familiar throughout Uzbekistan are joined by something that shows itself most strongly in the Aral Sea region — salt dust from the dried-up bed of the Aral Sea and heavily saline soils. Salt on steel and in concrete changes the rules of the game: a system that serves without trouble in Tashkent or Samarkand may last noticeably less here.
Three factors to take into account in the design
1. Salt in the air and on the surface
Where the sea dried up, the Aralkum salt desert has formed, and according to Uzhydromet’s assessment in the national climate communication (2024), Karakalpakstan is one of the regions of the country most exposed to dust and sand storms. The number of storm days in the republic has decreased over the decades, but across the country as a whole storms have become longer — they now more often last from 3 to 7 hours; on 27 May 2018 a salt storm from the Aralkum hit Karakalpakstan and Khorezm hardest of all. Studies of deposited dust show that it is rich in sulphates and chlorides (Opp et al., 2017), contains considerably more of them than dust from sandy deserts and is estimated to be more hygroscopic (reviewed in Xi et al., 2025). Settling on steel, such salts draw moisture from the air and form a thin film of electrolyte on the surface even in dry weather. If salt remains under a coating, osmotic blistering and underfilm corrosion start through it. Hence three rules: before painting, check the surface for water-soluble salts (methods of the ISO 8502 series, see corrosion protection quality control), wash the steel with clean water if necessary, and design structures without crevices and pockets where dust accumulates.
For exposed steel in such conditions, designers as a rule adopt a corrosivity category in the C3–C4 range, but it is checked separately for each site — to ISO 9223 or the descriptions in ISO 12944-2. The closer the facility is to sources of salt dust and the higher the required durability, the thicker the barrier and the more important the zinc-rich primer beneath it — see zinc-rich primers.
2. Saline soils and groundwater
According to the same national communication, 86% of the republic’s territory experiences an extremely high impact of natural and climatic factors because of the proximity of the Aralkum. Sulphates and chlorides in soil and water destroy foundation concrete and accelerate reinforcement corrosion, while buried steel — pipes, vessels, piles — needs protection designed for category Im3 (soil). In the codes of Uzbekistan these effects are addressed by ShNK 2.03.11-24: for concrete, through exposure classes, including those for chemical attack. For the below-ground parts of buildings and structures the solution is usually combined: durable concrete plus waterproofing, and for damaged structures, repair mortars.
3. Sharply continental climate
The west of the country receives about 100 mm of precipitation a year, warming in the Aral Sea region and on the Ustyurt Plateau is proceeding faster than in other parts of Uzbekistan, and severe frosts remain quite likely. According to Uzhydromet, Nukus has seen up to 46.0 °C in summer (2018) and down to −34.2 °C in winter (1973). Hot, dry summers, cold winters and large daily temperature swings subject thick coatings and grouts to cyclic stresses. Water-based materials must not be allowed to freeze during transport and storage, and in hot weather the working time of two-component products shortens.
The republic’s industry and typical tasks
Agriculture accounts for 29.6% of the republic’s gross product and industry for 23.6% (National Statistics Committee, 2022). According to reports from the President’s press service, chemicals, building materials, food, textiles and pharmaceuticals are growing fastest, a 1 GW wind farm is being built, and the siting of energy-intensive metallurgical, chemical and construction industries is being discussed; oil, gas and condensate fields are located on the Ustyurt Plateau.
- Gas production and gas chemicals. Pipe racks, vessel supports and the load-bearing structures of units are protected with fire protection tested to the hydrocarbon curve; pipelines and equipment under thermal insulation, with systems against corrosion under insulation (heat-resistant coatings).
- Chemical plants. Alkaline and saline media, spills, vessels and bunds call for chemical protection, which we select only on the basis of the questionnaire.
- Power generation. Fire protection of cable runs and turbine hall frames, grouting under turbine sets and pumps, and, for wind turbines, tower foundation grouts designed for fatigue and frost.
- Building materials. Dust, heat and heavy rotating equipment — heat-resistant systems and equipment grouting.
- Agriculture, processing, water management. Warehouses, processing workshops, pumping stations, water tanks: corrosion protection of steel structures and tank coatings; contact with drinking water requires a material with the appropriate approval — we check that it has one against the manufacturer’s documents.
Grouts and anchors in a saline environment
Under equipment that stands outdoors or next to spills of salt solutions, an epoxy grout is often more reliable than a cementitious one: it is denser and more resistant to salts. If the design calls for a cementitious grout, it is worth checking its sulphate resistance in the technical data sheet and not leaving exposed grout edges unprotected. Seismicity here is milder than in the east of the country: the republic is not included in the list of territories with an intensity of 8 and above annexed to Cabinet of Ministers Resolution No. 727 — the main enemy of anchors and grouts remains salt, not earthquakes.
Supply and support at a distance
Materials travel a long way to projects in Nukus, Khodjeyli, Beruni and other districts of the republic, so we put the delivery together in advance and, where possible, in a single batch: primer, intermediate coat and topcoat, thinners, consumables for inspection. Storage conditions — protection against frost and overheating — are agreed before dispatch. We carry out calculations, specifications and design reviews remotely; an engineer’s visit for a trial area or supervision is planned around the key stages of the work.
Similar conditions are found in Khorezm Region: that page has more on groundwater and humid workshops; the other regions are in the list.
Frequently asked questions from Karakalpakstan
How can steel be protected from salt dust?
Remove the salt before painting, choose a system with a sufficient barrier and a zinc primer, avoid crevices and places where dust collects, and during service inspect the coating regularly and touch up damage in good time.
Which grout will withstand a saline substrate?
The specific environment decides. Epoxy products are usually more resistant to salts; for cementitious ones, sulphate resistance must be confirmed by the manufacturer’s documents. Send us the site investigation data and we will select a material to match.
What about coating repairs at a site that is a long way to travel to?
Build them into the design from the very beginning: leave a repair kit of materials from the same system on site with a margin of shelf life, draw up simple instructions for the maintenance department and a plan of regular inspections. Minor damage sealed in time does not turn into a centre of corrosion under salt dust.
A project in Karakalpakstan — new or operating? Send us the site investigation data, a description of the environment and the schedule of structures, and we will propose a protection scheme that takes salt into account. We are available on +998 94 094 52 27 — we take calls and WhatsApp and Telegram messages; send design files to info@ognezashita.uz.