CASE STUDY
COLD PLATE BONDING
Belzona Cold Plate Bonding to Protect Corroded Walls
Industry: Mining
Application: Cold Bonding
Products: Belzona 1161, Belzona 9611, Belzona 5811, Belzona 5831
Customer Location: : WA, Australia
Application Date: March and July 2023
PROBLEM
A multiplate conveyor tunnel at a gold mine, situated below the water table, suffered extensive corrosion on its corrugated walls. A solution was required to reinstate the integrity of the existing tunnel walls.
Corroded overboard downpipe on a offshore platform
Prolonged exposure to offshore conditions resulted in leakage of the downpipe
APPLICATION
The selected repair method involved attaching patch plates to the lower sections of the tunnel walls.
After surface preparation was completed, thin wall areas were revealed where water behind the original walls was seeping through corroded holes. Belzona 9611 was successfully used to repair the live leaks, ensuring the surface was sufficiently moisture free in order to commence the repairs. First, the plates were placed in position in a dry fitting process. Thereafter, the prefabricated corrugated sheets were cold bonded in place with Belzona 1161. Finally, Belzona 5811 and Belzona 5831 were injected into the voids behind the panels to ensure superior bonding and additional corrosion prevention.
After surface preparation was completed, thin wall areas were revealed where water behind the original walls was seeping through corroded holes. Belzona 9611 was successfully used to repair the live leaks, ensuring the surface was sufficiently moisture free in order to commence the repairs. First, the plates were placed in position in a dry fitting process. Thereafter, the prefabricated corrugated sheets were cold bonded in place with Belzona 1161. Finally, Belzona 5811 and Belzona 5831 were injected into the voids behind the panels to ensure superior bonding and additional corrosion prevention.
Prior to the job being awarded, and to demonstrate that our products were suitable for cold plate bonding, we conducted a bond and pull test on corroded steelwork inside the tunnel, which was highly successful.
The images on the right show the test plate bonded to the corroded steel and the same plate after it was pulled off. After removal, the corroded steel pulled away, rather than the bond.
Cold bonding testing conducted prior to the order and approval
After removal, the corroded steel pulled away, rather than the bond
Following surface preparation, thin wall areas were revealed where water behind the original walls was seeping through corroded holes
Plugging the leaks after the surface preparation
Dry fitting of sheets
Plates bonded in place
OUTCOME
The panels were successfully bonded within the specified time frame, restoring the integrity of the existing tunnel walls while also providing ongoing corrosion protection.
Conveyor tunnel wall reinforced with plates using cold bonding
More Information?
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Products
Belzona 1161 (Super UW-Metal)
A 2-part composite material for metal repair and resurfacing based on a solvent-free, surface-tolerant epoxy resin reinforced with silicon steel alloy.
Belzona 5811 (Immersion Grade)
A 2-part epoxy coating which provides outstanding chemical resistance and protects equipment operating under immersion in aqueous solutions up to 50°C (122°F) from the effects of corrosion.
Belzona 5831 (ST-Barrier)
A 2-part epoxy coating which once cured forms a barrier coating for the protection of equipment operating under immersed conditions or in contact with aqueous solutions.
About Rezitech
Established in 1968, Rezitech is the sole Australian Distributor for Belzona. Rezitech offers a comprehensive range of industrial protective coatings and epoxy metal repair composites to many different industries including: oil and gas, mining, power, water and waste water, pulp and paper, marine, manufacturing among others.
We value growth and innovation within the maintenance solutions industry
Our Mission
To provide industry with easier maintenance solutions that provide cost effective, efficient and long lasting results for our valued clients. To provide an integrated industry service by striving for Rezitech being a truly complete solutions provider!
Our Values
We value the needs of our clients and place a huge emphasis on providing specialist skills and knowledge.
From engineering to fitting, blasting or coating to sales, administration and customer service, we highly value our organisation and encourage diversity andgrowth to benefit our client and our team of people.
Our Vision
To strive for excellence in our delivery of high quality industrial maintenance solutions. To be our clients’ preferred choice when it comes to solving all of their maintenance and new pump needs while helping to reduce their carbon imprint.
Health and Safety
Rezitech is committed to ensuring the health, safety and welfare of its employees, contractors, visitors and customers who may be affected by Rezitech’s operations. We strive to pursue standards of safety that meet and exceed statutory duties.
Community & Environment
While providing solutions for our clients Rezitech focuses on identifying ways to improve business environmental performance while increasing productivity and reducing costs of production for the benefit our clients and hence the community.
The Future
To continue to strive for excellence! To continue to lead the way in industrial maintenance solutions and services and provide our clientele with high quality, complete and reliable products and services.
Rezitech’s mission is to make its liquid ring vacuum pump expertise available to sugar mills, paper mills and process industries worldwide. We currently export to:
- Fiji
- Thailand
- Mauritius
- Indonesia
- United Kingdom
- Phillipines
- Malaysia
- New Zealand
- Papua New Guinea
We are constantly on the look out for new export opportunities and new countries to export to Rezitech places an emphasis on the development of export business worldwide.
For further information on a Flowtech Distributorship please contact us.
