CASE STUDY
FLARE OUTLET PIPEWORK RESTORATION
Belzona SuperWrap ll Reinforces Complex Flare Outlet Pipework
Industry: Oil & Gas
Application: Flare Outlet Pipework Reinforcement
Products: Belzona 1161, Belzona SuperWrap ll Composite Wrap
Customer Location: VIC, Australia
Application Date: Dec 2025
PROBLEM
Corrosion and localised metal loss were identified on carbon steel flare outlet pipework at an oil and gas facility, requiring immediate repair.
The affected section included a branch connection, creating complex pipe geometry within the repair area. The repair needed to restore and reinforce the deteriorated pipework while closely conforming to the existing pipe profile and branch connection.
Deteriorated flare outlet pipework
APPLICATION
A combination of Belzona 1161 and the Belzona SuperWrap II composite repair system was selected to restore and reinforce the damaged pipework.
Prior to application, the surface was prepared by abrasive blasting to Sa 2½ and checked to ensure it was free from surface contamination.
Following preparation, areas of pitting and surface irregularity were rebuilt and profiled using Belzona 1161. This created a smooth, continuous profile around the branch connection and prepared the pipe geometry for the application of Belzona SuperWrap II.
The pipework was then reinforced using the Belzona SuperWrap II system consisting of Belzona 1983 resin, Belzona 9381 reinforcement fabric and Belzona 9382 consolidation film.
The Belzona SuperWrap II system was applied following the steps in the Belzona SuperWrap II T Piece repair scope, allowing the reinforcement to suit the main pipe and branch connection geometry.
Blasted pipe surface prepared for Belzona application
Pipe profile rebuilt and smoothed using Belzona 1161
Belzona SuperWrap II reinforcement applied around the branch connection
Completed SuperWrap II repair reinforcing complex pipe geometry
OUTCOME
The completed Belzona SuperWrap II repair delivered effective, reliable reinforcement across the damaged section and around the branch connection, demonstrating how composite repair technology can restore complex pipework geometry and help extend asset life.
More Information?
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Products
Belzona SuperWrap II
Composite repair system, Belzona SuperWrap II, offers a new generation repair solution for restoring the strength of holed, weakened and corroded pipe and tank walls. It is comprised of a fluid-grade resin system, a bespoke hybrid reinforcement sheet, based on fibre glass and carbon fibre, as well as a release film to compact and consolidate the application.
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. This composite material is specifically designed for application to wet and oil contaminated surfaces, as well as for underwater applications. It is easy to mix and apply without the need of specialist tools and can be machined using conventional tools.
Frequently asked questions
How was the corroded flare outlet pipework repaired without replacement?
The deteriorated carbon steel flare outlet pipework was repaired using Belzona 1161 (Super UW-Metal) together with the Belzona SuperWrap II composite repair system. Belzona 1161 was used to rebuild and smooth areas of metal loss before SuperWrap II was applied around the main pipe and branch connection to provide composite reinforcement.
Why was Belzona SuperWrap II suitable for the complex branch connection?
Belzona SuperWrap II can be applied around complex pipe geometries, including branch connections and other difficult shapes. In this project, the reinforcement was able to closely conform to the flare outlet pipework and branch connection, allowing the deteriorated area to be strengthened without replacing the affected pipe section.
How was the flare outlet pipework prepared before the composite repair was applied?
The carbon steel pipework was abrasive blasted to Sa 2½ and checked for surface contamination. Areas of pitting and surface irregularity were then rebuilt and profiled with Belzona 1161, producing a smooth, continuous profile suitable for application of the Belzona SuperWrap II system.
What products were used for the flare outlet pipe reinforcement?
The repair incorporated Belzona 1161 (Super UW-Metal) for rebuilding and profiling, followed by the Belzona SuperWrap II system, consisting of Belzona 1983 resin, Belzona 9381 reinforcement fabric and Belzona 9382 consolidation film.
What was the outcome of the Belzona SuperWrap II flare outlet repair?
The completed repair provided continuous composite reinforcement across the damaged pipework and around the branch connection. The system restored reinforcement to the deteriorated area while accommodating the complex geometry and avoiding the need to replace the affected section of flare outlet pipework.
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.
