Success Stories

Plascoat plastic coating products


Our products are used in a wide variety of different applications and here you will find case studies on the most common ones. Be reassured that many of our products have been tried and tested over many years and offer real long-term value. If you have a coating job not covered by any of our case studies then one of our technical specialists will be happy to advise.

Domestic white goods

Plascoat NG30 - a new breed of polyethylene fluid bed coating powder

NG30 offers free flowing properties that allow good edge coverage, with minimal overall coating thickness at a considerably lower pre-heat temperature. Designed for the wire-work market, NG30 is available in a non-yellowing white, which will provide long lasting protection for your wire items.

Reports from users indicate savings as follows:

- up to 30% lower material usage
- up to 50 deg. C (even 100 deg. C in some cases) reduction in coating temperature – and therefore energy usage
- up to 15 % reduction in cycle times
compared to traditional polyethylene fluidised (fluidized) bed coating powders.

Typical applications include refrigerator shelves, dish drainers, freezer and closet shelving.

Talisman 10 - coating of dishwasher baskets

Success story for more than a decade

After five years in a demanding market place a leading Asian dishwasher manufacturer has announced that New Talisman 10 has "exceeded expectations" in both operation and cost. In addition, other appliance manufacturers in Asia have shown that the coating will last in excess of 7000 cycles - equivalent to over 15 years.

Talisman 10 is now being used by a number of Appliance manufacturers in Europe, Asia and USA and has been used to coat the baskets of at least 2m dishwashers.

Talisman 10 is a thermoplastic coating that has been specifically developed by Plascoat to provide outstanding performance in the field of dishwasher baskets, freezer shelves and glass-washer baskets. It provides protection for the metal in such environments and meets the performance at lower cost to traditional alternatives.

In addition to a significant cost advantage over nylons, Talisman 10 also shows some distinct performance benefits. These have been demonstrated in extensive field and laboratory tests - both at Plascoat and at appliance manufacturers themselves.

For instance, after four months at 130°C, Talisman 10 showed no signs of degradation or discolouration, whilst its nylon equivalent yellowed after just 72 hours. In salt-spray tests after 500 hours on deliberately damaged plates, New Talisman 10 showed only a few millimetres loss of adhesion, whilst the nylon coating's adhesion had been completely lost.

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Metal fences

Abcite X60 - Metal fences at Brussels Airport (Belgium)

Zaventem Airport in Brussels initiated a project to renew the metal fences, which are used as both security and noise protection for the airport personnel.


Abcite X60 - Security fences in Antwerp (Belgium)

A villa standing in a residential quarter of Antwerp had to be partially fenced in to protect it against potential burglars. Two security gates were to form part of the fence (80 meters long and 180 centimetres high) and give access to the property. All elements had to fit with this posh part of town and at the same time be resistant to climatic influences and to vandalism.

Plascoat PPA 571 - top performer in Australia

In 1996 a local Brisbane coating company recommended Plascoat PPA 571 in a tender to remove, sand blast, re-coat and re-install fences in Sutton Beach, one of Brisbane’s seaside parks. Whilst it took only 6 months for the previous chosen coating technology to corrode completely, fences coated with Plascoat PPA 571 still look like new today.


Plascoat PPA 571 - security fencing for hot climates (UAE)

The climate in the United Arab Emirates is very demanding on coated metal. Sacrificial zinc, polyester and PVC coatings can be quickly stripped off the metal by wind-blown sand. Very high levels of UV can also cause coatings to degrade and fail after just a few years. Due to its outstanding performance on corrosion resistance, UV stability and abrasion resistance, Plascoat PPA 571 has been chosen to do the job. 18 years after installation the fence is still in place without any damages.

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Marine environment

Abcite 545 - Perforated steel façade exposed to marine conditions

With its 8.6 million visitors per year, Copenhagen’s Fisketorvet shopping mall, located in the old inner harbour area, perfectly illustrates the challenges of building an asset in a maritime zone. In 2000, the Danish building contractor of the mall decided to use perforated sheet steel to conceal fire escapes and other projections attached to the masonry of building. After carefully testing several alternatives, Abcite 545 was chosen as the coating solution for this job.


Abcite X60 - ABB Cewe for Göteborg Energi (Sweden)

The climatic conditions of a city like Göteborg make corrosion protection a real challenge. Conventionally painted cable cabinets cannot withstand this tough environment.

After several tests including real time exposure, Göteborg Energi chose Abcite for the protection of all cabinets installed in the urban community.

Plascoat PPA 571 - top performer in Australia

In 1996 a local Brisbane coating company recommended Plascoat PPA 571 in a tender to remove, sand blast, re-coat and re-install fences in Sutton Beach, one of Brisbane’s seaside parks. Whilst it took only 6 months for the previous chosen coating technology to corrode completely, fences coated with Plascoat PPA 571 still look like new today.


Plascoat PPA 571 -  North Sea case study

Optimising key assets in a harsh environment

The high cost of maintaining and operating offshore production facilities is felt no more keenly than in the North Sea. Structures face a constant challenge from corrosion and abrasion. Metal becomes degraded, losing its strength and this can eventually lead to premature, sometimes sudden, failure. Protection of the metal is the job of metal surface finishing. 2010 some of the railing structure have been coated with Plascoat PPA 571 whilst another part with other technology. Have a look at the details.


Plascoat PPA 571 -  playground on Spanish beach

A playground exposed to tough conditions

A popular children's playground on the beach at San Sebastian in Spain was given a new lease of life with Plascoat PPA 571. Although the imaginative steel structure was providing enjoyment to more than 3000 children a week, the effects of saltwater corrosion soon became apparent.
The playground, which was previously coated in epoxy-polyester, stood little chance against the demanding elements. During the winter months it had no protection from salt, sand and water corrosion from the Atlantic rollers that crashed over the exposed site. In the summer intense UV rays added to the deterioration with rust becoming a serious problem. The damage was so bad that the playground had to be closed for repair and refurbishment in October 2000.

The town planners were delighted when they were informed about the protective qualities of Plascoat PPA 571, a thermoplastic coating which has repeatedly proved itself in just these sorts of demanding environments. Subsequently the playground was restored and completely recoated with PPA 571.


Plascoat PPA 571 - harbour protection (Monaco)

Plascoat PPA 571 has played an important part in the improvement of Monaco's Port Hercule harbour with the involvement in the construction of a new breakwater.
A major construction project was launched by Prince Rainier in 2002, aimed at increasing the protection for Port Hercule, to improve the capacity for pleasure craft and to allow the docking of larger cruise liners at the popular Monaco marina.
The project, which consists of a 352 metre long, partially floating breakwater and a fixed counter jetty has been responsible for turning Monaco into one of the most important pleasure boating ports in the Mediterranean.
Safety and long-term maintenance played a vital part in the development of the construction. Safety was paramount and an important part of the design was to stop swimmers and divers been potentially dragged by undercurrents into the hollow concrete structure. As a result, the sub-surface of the breakwater contains a series of steel rods and mesh panels that act as a protective grill, preventing swimmers from being caught inside. Plascoat PPA 571 has been used to provide essential long-term durability for the submerged steel elements of the structure because of its successful track record in this type of environment.
Plascoat PPA 571 composition means that it does not actively support the growth of barnacles, therefore long-term maintenance costs of the structure are kept to a minimum.


Plascoat PPA 571 - Lamp posts (La Réunion)

The tiny island of La Réunion in the Southern Indian Ocean, just south of Madagascar is a surfer's paradise. However, the severe tropical climate means that street furniture, particularly at the sea front, needs a world-class coating to protect it from severe conditions. The fishing village of St. Leu known as "Surf Mecca" is home to one of the most famous waves in the world and hosts many surfing competitions including the famous "Rip Curl" World Cup which took place there in 1999. As preparation for this world-class event, the sea front at St. Leu was refurbished. This included coating the lamp posts and flag masts with Plascoat PPA 571. The esplanade was made immaculate and the coating is still pristine today.

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Battery boxes

Plascoat PPA 691 - One of the most used coatings in the European battery box industry

Manufacturers in Germany, the UK, France, Netherlands, Belgium and Italy are among the countries to welcome Plascoat PPA 691 as well as the top-of-the-range PPA 571 fluidised bed applied alternative.

Battery boxes in excess of a cubic metre are now being dipped in PPA 691. The application of this powder, to a typical thickness of 600-800 microns, provides a smoother finish at lower temperatures at a cost around half that of a polyurethane coating.
PPA 691 is available in a wide range of colours to RAL specification, to compliment most electrically powered vehicles.
The grade of thermoplastic coating Plascoat PPA 691 has been developed for specific use on battery boxes for electrical powered vehicles in hazardous dusty environments where the risk of explosion from sparks could be potentially hazardous and to meet the requirements of ATEX. The coatings are fully resistant to chemical attack including battery acids, offers high impact protection and excellent long-term adhesion, preventing any metal, once coated from becoming exposed and conductive.

Plascoat also offer PPA 571 and PPA 571H for the coating of battery boxes.

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Pipes and fittings

Plascoat PPA 571 HES - maximising the life cycle of buried metallic components

The water distribution system in Calgary, Alberta, Canada, is benefitting from using a high-performance coating on its iron waterworks and fittings. Plascoat PPA 571 HES, one of the PPA 571 family of thermoplastic coatings, is protecting these vital components and helping to reduce maintenance costs and extend the life of buried components. The coating has NSF61 approval and is BPA free.


Plascoat PPA 571 - water pipe protection in Seattle, USA

Superior protection and labour-saving benefits

Seattle Public Utilities declared Plascoat PPA 571 to be its ‘coating of choice’. As well as noting the exceptional protection against corrosion and low maintenance the company also appreciated the labour-saving benefits it offered during installation, in soils that would be hazardous to personnel if subjected to prolonged exposure.


Abcite X60 - Swimming pool Antwerp (Belgium)

Swimming pools are difficult environments. The high humidity, the presence of chemicals and the permanent exposure to human traffic are a gold mine for corrosion.

In February 2010, during the renovation of the swimming pool, 34 metres of handrails, 26 metres of tubes, 27 metres of balustrades and several steps or grilles were spray-coated with 500 µm Abcite® X60 in RAL 9002.

Plascoat PPA 571- ductile iron pipe coating (Gothenburg Water and Sewage, Sweden)

The Gothenburg Water and Sewage works serves about 450,000 inhabitants and industries. Water is taken from the Göta river and after treatment in two plants distributed in a network, 1750 meters in length.
Traditionally cast-iron pipes were used but in 1970 ductile iron pipes were introduced. The soil consists of either rock, glacial clay with a high salt content. Corrosion is a well-known phenomenon and many old pipes have been replaced over the years, but still there are a considerable number of pipes from the last century in service. Typically, there have been 300-400 failures with these pipes on the main network every year.
In 1986, however, new pipes were coated in thermoplastics and in the last few years in Plascoat PPA 571ES. Since this change, 80 km of pipe have been installed and so far there has been no instance of failure or corrosion with these pipes. As a result of this experience, and of controlled tests by the Swedish Corrosion Institute, Plascoat PPA 571 is now being increasingly used for the coating of ductile iron pipes, fittings and hydrants around the world.


Plascoat PPA 571ES - water tank protection in Italy

A leading manufacturer of water tanks and water treatment equipment is one of the latest water treatment companies to switch successfully to Plascoat PPA 571ES. Previously using wet paints, the tanks continually suffered from corrosion problems. However, the introduction of the innovative PPA 571ES has now given the company an effective long-term solution.
PPA 571ES offers the advantages of perfect edge and weld coverage, pinhole free coating, high chemical resistance - in particular to chlorinated water at a concentration of 28 ppm and excellent resistance to sea water.

Construction projects

Abcite X60 - coating for bridge design elements (Belgium)

When a new bridge was built in Kortrijk, Abcite was chosen for the protection of the balustrade. In addition to the perfect long-term weathering resistance requested for such a project, the chemical resistance (salts for de-icing and vehicle exhaust gas) of the coating was an important consideration when selecting the coating. After a sand blasting as surface preparation, the welded grilles of the bridges were sprayed with 500 µm Abcite X60 in NCS 7500 N, a specific colour chosen by the architect.


Abcite 545 - Perforated steel façade exposed to marine conditions

With its 8.6 million visitors per year, Copenhagen’s Fisketorvet shopping mall, located in the old inner harbour area, perfectly illustrates the challenges of building an asset in a maritime zone. In 2000, the Danish building contractor of the mall decided to use perforated sheet steel to conceal fire escapes and other projections attached to the masonry of building. After carefully testing several alternatives, Abcite 545 was chosen as the coating solution for this job.


Abcite X60 - ABB Cewe for Göteborg Energi (Sweden)

The climatic conditions of a city like Göteborg make corrosion protection a real challenge. Conventionally painted cable cabinets cannot withstand this tough environment.

After several tests including real time exposure, Göteborg Energi chose Abcite for the protection of all cabinets installed in the urban community.

Plascoat PPA 571 - the perfect solution for Spanish climate

Projects like Pasarela Peatonal de Anorga, a 25-metre local authority footbridge over a railway line near the Northern coastal town of San Sebastian in Northern Spain required a new type of coating as, after only a few months, the polyamide coating began to peel from the sections. The search was on for a coating that could accommodate the wide temperature range, provide a high level of UV resistance, resist to vandalism, meet the requirements of a tightening budget, and offer a coating life in excess of 10 years.
Plascoat PPA 571 was the answer with its high level of durability and weatherability and long-term adhesion to both steel and aluminium and became a perfect test site for Plascoat PPA 571.  

1990 the green structure was coated in Plascoat PPA 571 whilst the red handrails were originally polyester coated. You can see that after 18 years the PPA 571 coating still looks "like new" whilst the handrails have had to be repainted three times. In addition, an area on the poles was deliberately uncoated; after 18 years by the sea there is no under film corrosion or blistering.
Another project where Plascoat were called upon to provide a solution involved the Paris based engineers, Freyssinet, who were managing a project to construct the Colindres Viaduct. After only six months the previous coating had deteriorated and started to peel off under the effects of UV rays, salt attack, and extreme temperatures. Once again, therefore it was the demanding climate that would be the principal reason PPA 571 was chosen.
Since re-coating all of these parts in PPA 571 (around 650, 3 metre, 200-300 diameter tubes – nearly 2 km in all) the effects of the worst of the Spanish weather, salt and traffic pollutants have failed to take the gloss off Plascoat PPA 571.


Plascoat PPA 571 - Building Regulations 2000 - access and use of buildings, M1 and M2

"Warm to the touch" coating for new handrail regulations

Plascoat PPA 571 is taking the industry by storm following tests showing that it is one of the warmest-feeling coatings on the market. This feature is now proving to be a major breakthrough in the face of building regulations in the United Kingdom.
May 2004 saw the introduction of the UK's Building Regulations 2000, Access to and Use of Buildings, Part M1 and M2 stipulating the handrails needed to be "slip resistant and not cold to the touch".
One key attribute of Plascoat PPA 571 is a tactile quality that gives a 'warm to the touch' feel.
Unlike traditional coatings such as wet paints, polyester or PVC based products, Plascoat PPA 571 chemical make-up is such that it is an excellent thermal insulator making it warm to the touch even in winter. In fact, the colder the ambient temperature - the more noticeable the warmth of the coating. In single coat applications, thicknesses of 170 to 300 microns (7-12 mils) can be achieved, and by flock-spraying or fluidised bed dipping, up to 750 microns (30mils) can be attained, preventing heat from the hand transferring to the metal surface.
Another key feature of Plascoat PPA 571 in the light of the new regulations is that although extremely smooth and glossy, the surface is also slip resistant. It is available in a wide range of colours and more recently, in various finishes ensuring that the aesthetic appeal of a coating can be considered as well as compliance with the UK's new regulations.
Typical examples include the Riverside Housing Development in Gateshead, Kingston upon Thames Hospital, the London Science Museum and the Colchester Army Barracks.

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Playground

Plascoat PPA 571 -  playground on Spanish beach

A playground exposed to tough conditions

A popular children's playground on the beach at San Sebastian in Spain was given a new lease of life with Plascoat PPA 571. Although the imaginative steel structure was providing enjoyment to more than 3000 children a week, the effects of saltwater corrosion soon became apparent.
The playground, which was previously coated in epoxy-polyester, stood little chance against the demanding elements. During the winter months it had no protection from salt, sand and water corrosion from the Atlantic rollers that crashed over the exposed site. In the summer intense UV rays added to the deterioration with rust becoming a serious problem. The damage was so bad that the playground had to be closed for repair and refurbishment in October 2000.

The town planners were delighted when they were informed about the protective qualities of Plascoat PPA 571, a thermoplastic coating which has repeatedly proved itself in just these sorts of demanding environments. Subsequently the playground was restored and completely recoated with PPA 571.

Plascoat PPA 571 - adventure playground (Jumeirah, Dubai)

Since it opened in 1996, more than 75,000 children have enjoyed one of the best adventure playgrounds in the world at the Jumeirah Beach Hotel in Dubai.

Plascoat PPA 571 has no small part to play in its success. The coating has proved its durability and longevity and, continues to provide unbeatable protection for the steel framework. The one-acre playground has proved to be a valuable asset to the hotel's facilities and is certainly a popular attraction to the younger guests at this world class hotel complex.

The coating has demonstrated beyond doubt its capability to withstand the harsh effects of coastal salt, intensive UV rays, 100% humidity, high desert winds and rapid temperature fluctuations as well as the wear and tear of over 75,000 children who have taken pleasure in the playground since it opened.

Cable trays

Abcite 545 - cable ladder protection at Electrabel Suez Wilhelmshaven Germany

Electrabel / Suez specified Abcite 545 for the protection of the 5 km of steel cable ladders, a total of 4,000 m² of surface to be coated. The coating had to withstand industrial and maritime climate including the sulphur fumes typically found at coal-fired power plants.

Plascoat PPA 571 - coating cable trays and supports for water treatment plant (Hong Kong)

Plascoat PPA 571 has been used for the coating of cable trays and supports for the Au Tam Mei water treatment plant in Hong Kong.
The application demanded a high degree of corrosion protection due to the high humidity and UV levels on a coastal location experiencing constant salt attack.
The greater protection properties of the thick film PPA coating, fluidised bed dipped to 250 micron over the galvanised mild steel cable trays, was another factor in the decision to move away from paint, PVC or Duplex coating systems.
Other considerations were that PPA 571 was halogen free, and of extremely low toxicity and low smoke levels in the event of fire. PPA571 meets the requirements for low smoke of the US Federal Railroad Administration and London Underground.

Further examples on Cable trays references are:

  • Shek Wu Hui sewage treatment expansion
  • Junk bay Drainage Services station
  • Tsing Yi bridge
  • Dragonair Building - Chek Lap Kok Airport
  • Princess Margaret Hospital
  • Ngau Tam Mei Water Treatment Plant
  • Sheung Shui Slaughterhouse Plant
  • Teing Yi Duplicated South Bridge
  • Hutchinson Cellular ‘Phone Repeater Station
  • Cheung Kwan O Hospital
  • Stone Cutter Island Drainage Services Station
  • Tuen Mun No.38 Drainage Services Station
  • Fee O Lan Radar Station
  • Hutchinson Cellular ‘Phone Repeater Station in CLK Airport
  • Brussels Metro

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Street furniture

Plascoat PPA 571 - Jackson Bridge restoration, USA

In 2011 Pendry Coatings recommended Plascoat PPA 571 in a tender for required restoration work on Jackson Street Bridge in Indiana, USA. The work involved the removal, re-conditioning, re-coating and re-installing all steelwork on the bridge. This included lighting columns, crash barriers, railings, and public information boards.


Plascoat PPA 571 - lamp post coatings, UK

A UK high volume specialist manufacturer of lighting columns was asked in 2011 to supply columns for several high-profile street lighting Private Finance Initiative contracts, where the local authority had secured government funding to replace the existing lighting. As specialists in the manufacture of highly engineered lighting column, traffic sign column and bespoke support structures, this company carefully considered the options for anti-corrosion treatments to complement hot dipped galvanizing. Most of the company's products spend their entire lives standing up to the elements - rain, frost, snow, heat and UV–rays. Some are partly submerged below ground where a new set of elements impacts, including high levels of acid or alkaline in the soil which can cause hidden corrosion. In order to produce a winning tender, they knew that whole life costs were as important a consideration as the upfront cost. The old redundant lighting columns had been wet painted on site and other manufacturers tendered for the contracts using various different paint systems.

This specialist UK lighting column manufacturer chooses a different route. As Alan Paterson, Managing Director explains:  "We knew that we could offer significant savings by using Plascoat PPA 571, a highly durable thermoplastic coating, for the columns. PPA 571 has exceptional properties that offer outstanding protection against corrosion. The columns last far longer in the ground than painted columns would. The coating is tough and doesn't chip or crack so further savings are achieved as there is never a need to repaint on site. The whole life savings to the contractor and the client are substantial. Using PPA 571 also means that we avoid the lengthy drying process of wet sprayed coating and our product can be manufactured and installed on time, even in bad weather. The appearance of street lighting columns is important too. Local authorities aim to provide a well-maintained street environment. PPA 571 is an attractive high gloss finish and provides little or no anchor for the growth of algae or fungus which would spoil the look of these structures. So, in short, the columns will continue to look good and will not need repairing or replacing over a twenty-five-year period. We felt our clients couldn't lose."

Plascoat PPA 571 proved to be a winning finish and the company secured the tenders, undertaking to initially replace and subsequently maintain street lighting for 25 years.

Plascoat PPA 571 - coating 100,000 lamp posts in Stockholm, Sweden

The Swedish Union of Local Authorities revealed in 2009 that they have coated over 100,000 lamp posts in Stockholm and other Swedish cities with Plascoat thermoplastic coating PPA 571. 25 years after the first trials of thermoplastic coatings in Sweden began; Plascoat PPA 571 has become the coating of choice for the Swedish authorities that have clearly overcome the problem of the short lifespan and the expense of constantly replacing lampposts.

Although lamp posts may not appear to be situated in the harshest of environments, they do suffer from a wide variety of corrosive substances above, below and particularly at ground level where dogs frequently contaminate the environment.

Trials at the Swedish Corrosion Institute have proved that thermoplastic coatings such as PPA 571 are one of only three out of 52 corrosion protection systems that can extend the lifetime of a lamp post by up to 50 years.

In addition to the well-known benefits of the coating, it also offers extreme resistance to budding graffiti artists. Even the most enduring of paints can easily be wiped clean, as can problematic fly-poster adhesives.

"Ground level corrosion on lamp posts can cause a real hazard. Using a protective coating such as PPA 571 means that the lifetime of the lamp post is greatly increased, and the cost of maintenance is reduced. The hidden costs of road closures and inconvenience to road users are often rarely factored into these costs. The fact that 100,000 lampposts in Sweden are now coated with PPA 571 is clear testament to both the quality and the benefits of the product."


Plascoat PPA 571 - Lamp posts (La Réunion)

The tiny island of La Réunion in the Southern Indian Ocean, just south of Madagascar is a surfer's paradise. However, the severe tropical climate means that street furniture, particularly at the sea front, needs a world-class coating to protect it from severe conditions. The fishing village of St. Leu known as "Surf Mecca" is home to one of the most famous waves in the world and hosts many surfing competitions including the famous "Rip Curl" World Cup which took place there in 1999. As preparation for this world-class event, the sea front at St. Leu was refurbished. This included coating the lamp posts and flag masts with Plascoat PPA 571. The esplanade was made immaculate and the coating is still pristine today.


Plascoat PPA 571 - top performer in Australia

In 1996 a local Brisbane coating company recommended Plascoat PPA 571 in a tender to remove, sand blast, re-coat and re-install fences in Sutton Beach, one of Brisbane’s seaside parks. Whilst it took only 6 months for the previous chosen coating technology to corrode completely, fences coated with Plascoat PPA 571 still look like new today.

Stadium seatings

Plascoat PPA 571 (ES) - exterior weathering capabilities for stadiums around the world

Projects to construct and refurbish stadiums around the world have benefited from the exterior weathering capabilities and durability of Plascoat PPA 571 (ES).

The electrostatic spray version has proved a major success with manufacturers of metal stadium seating where a long-lasting durable finish at a cost-effective price is the requirement.

Among the prestigious stadiums that have benefited from a PPA 571 finish are; the Wimbledon No.1 court, the Sultan of Brunei’s stadium, and numerous soccer and rugby football stadiums – including the Harlequins and Old Trafford – the home of Manchester United.

Stadium Seating reference list:

  • Bahrain Grand Prix Racing Track
  • Celtic Football Club - Scotland
  • Camel race track - Dubai
  • Molde Football Club - Norway
  • Croker Park Stadium - Ireland
  • Neptune Baseball Stadium - Holland
  • All England Lawn Tennis & Croquet Club (Wimbledon)
  • Arsenal Football Club - England
  • Millennium Stadium - Cardiff, Wales

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