Belzona Composite Repairs
What is the problem?
Pipes, vessels, tanks and other equipment can suffer from internal erosion and corrosion as well as external environmental attack which compromise their performance. This damage can lead to thin wall or even through wall defects.
These problems can have costly implications including:
- Increased safety concerns
- Higher operating costs
- Unplanned outages
- Shorter service life
- Frequent maintenance expenses
Damaged pipework can be repaired by cutting out the affected section and replacing it by welding in a new section. This requires production to be stopped and involves hot work, which can lead to costly downtime, safety hazards and serious environmental issues if risks are not carefully managed.
Belzona cold curing composite repair materials can return strength to weakened or holed pipes, vessels, tanks and other equipment, avoiding hot work and shutdowns, improving safety and providing corrosion resistance for the long term.
Our repair composite materials offer:
- On or offline repair
- No hot work
- Surface tolerant options
- Rapid return to service
- High bond strength
- Longevity in service
What makes us different?
- Repairs undertaken at a fraction of the cost of equipment replacement
Belzona cold curing solutions can be quickly applied in-situ for a fraction of the cost of conventional repairs or replacement, ensuring significant savings in time and money. Our materials provide a quick return to service, avoiding extended downtime, production losses and often outlast the original equipment.
Ease of use and safety
- Reduced health and safety risks as our materials are solvent free
Belzona composite materials are solvent free, easy to apply and cure at ambient temperatures. They eliminate the need for hot work, making them as safe as possible to use.
- Materials compliant to a range of national and international standards
Belzona materials have been extensively tested to the highest possible standards by independent organisations and customers to ensure they offer optimum adhesion and resistance.
- Belzona SuperWrap II, our compliant pipe repair system complies with ASME PCC2 and ISO 24817.
- Many of our products are suitable for contact with potable water, meeting ANSI/NSF Standard 61, UK WRAS and other national and international standards.
- Heat and chemical resistance
Belzona composite repair materials provide excellent corrosion resistance with proven resistance across a wide temperature range and against numerous aggressive industrial chemicals.
What is the problem?
Thin and through wall defects caused by internal erosion, general erosion-corrosion, impact damage and corrosion under insulation are common problems that affect pipes, tanks, engine casings, wear pads and other pieces of equipment. In addition, damage caused by abrasion due to movement between mating surfaces or joint leakage caused by vibration can also result in similar damage.
The Belzona solution
Difficulties associated with the use of repair methods such as patch welding can be prevented by using a Belzona cold bonding epoxy resin solution. Our solvent free materials offer high pressure retention while demonstrating exceptional bond strength. The Belzona repair uses cold curing materials such as Belzona 1111 (Super Metal) to bond repair patches over damaged areas. For bonding over manually prepared oil or water contaminated surfaces Belzona 1212 provides an ideal solution to repair damaged equipment.
Alternatively, a liquid grade material such as Belzona 5811 (Immersion Grade) can be used for larger plate bonding applications or where complex geometries are involved as an alternative to high risk repairs associated with hot work. The material can be simply injected behind the plate to quickly bond it permanently in place.
What is the problem?
Pipework is susceptible to corrosion, erosion and mechanical damage. If these problems are not addressed on time, asset integrity can suffer and there is a high probability that environmental and safety hazards occur. It is critical to return strength to the weakened or holed pipework or pipelines quickly in order to minimise equipment downtime.
Belzona composite wraps
Reinforced Belzona wraps are ideal for the permanent repair of low pressure, non-critical equipment. Belzona wraps can be applied in-situ and the pipework will not require stress relieving following application. In addition, these cold curing repairs can take only a few hours to complete.
Depending on the application situation, different epoxy composite materials can be specified for wrap repairs. Belzona 1111 (Super Metal) is suitable for many general applications. Depending on the size of the repair area, cure time may be extended with Belzona 1121 (Super XL-Metal) or shortened with Belzona 1212. This material is engineered for in-situ application to oil contaminated, wet and underwater surfaces and exhibits rapid cure and excellent adhesion to manually prepared substrates.
These paste grade materials are applied incorporating a high strength woven reinforcing sheet which provides strength to the repair.
Belzona compliant wraps
For situations where a fully compliant repair is required, Belzona SuperWrap II has been developed in compliance with international standards ISO 24817 and ASME PCC2. This versatile system provides a downtime saving alternative to welding and its cold curing ability enables corrosion damaged components to be back online within as little as 24 hours. Belzona SuperWrap II is supplied as a 2 part epoxy resin system with a reinforcing sheet and release film can be applied in-situ to pipes and vessels operating at different temperatures and high pressures.
The versatility of the system also allows for applications to any geometry of piping including bends and tees and resists a wide range of chemicals, oils and process fluids. By offering a design life longer than the anticipated asset life of the component, Belzona SuperWrap II provides a durable repair.
Live Leak Repair:
What is the problem?
Internal or external corrosion leads to thinning of pipe walls which eventually can result in leaks. This presents major safety concerns as leakage of potentially harmful solutions into the environment can prove problematic to both personnel and equipment in the immediate vicinity. In addition, leaking pipes can also lead to a pressure drop which result in a reduction in efficiency of the process.
If equipment is actively leaking, the leak must be stemmed prior to the application of one of the Belzona long-term repair composite materials. Our range of rapid curing epoxy resin materials can seal these leaks, providing fast repair and high abrasion and chemical resistance.
Live leaks at low pressures can be stemmed effectively by using Belzona 1291 (ES Metal), a rapid curing epoxy packaged as a stick and designed specifically to seal live leaks, followed by a Belzona wrap to achieve a permanent repair.
Where higher pressure repairs must be completed while the equipment is leaking, vent plates can be bonded in place using materials such as Belzona 1212 which can bond to oily and wet surfaces. Once the Belzona material has solidified, the vent can be closed, stopping the leak. Other equipment elements can also be bonded, such as small bore nozzles and flanged joints.