CASE STUDY
PIPEWORK RESTORATION AND REINFORCEMENT
Belzona SuperWrap ll Reinforces Complex Corroded Pipework
Industry: Oil & Gas
Application: Pipeline Repair and Protection
Products: Belzona 1161, Belzona SuperWrap ll Composite Wrap
Customer Location: VIC, Australia
Application Date: Jan 2025
PROBLEM
A carbon steel pipeline at an oil and gas facility was showing significant external corrosion and surface deterioration and required immediate repair.
Adding complexity to the project were two existing nozzles within the repair area that also needed to be made redundant and permanently encapsulated. Instead of replacing the damaged pipe section, the project team sought a solution that would strengthen the existing asset, extend its service life and minimise the disruption associated with conventional replacement work.
Corroded pipe section showing the redundant nozzles
APPLICATION
Belzona SuperWrap II was selected to provide a durable composite repair solution for the deteriorated pipework.
Areas affected by corrosion and surface loss were abrasive blasted and rebuilt with Belzona 1161, restoring the pipe profile while building up and smoothing the areas around the redundant nozzles to provide a suitable surface for composite reinforcement.
Thereafter, the section was reinforced using the Belzona SuperWrap II system, combining Belzona 1983 high-temperature resin with Belzona 9381 reinforcing fabric to form a high-strength composite repair. Multiple layers were applied to create a continuous wrap around the complex geometry.
Pipe profile rebuilt with Belzona 1161
Application of Belzona SuperWrap II over Belzona 1161
Application of the Belzona SuperWrap II composite repair system
Completed Belzona SuperWrap II repair
OUTCOME
The Belzona SuperWrap II repair successfully reinforced the deteriorated pipework, accommodating the redundant nozzles and complex geometry without the need for replacement.
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 can corroded pipework be repaired without replacement?
Corroded pipework can be restored in situ using a composite repair system such as Belzona SuperWrap II. In this project, the damaged pipe profile was rebuilt with Belzona 1161 before the pipe was reinforced with the composite wrap, avoiding full section replacement.
Can Belzona SuperWrap II be applied around complex pipe geometry?
Yes. Belzona SuperWrap II can conform to complex geometries. In this repair, the system was successfully applied around two redundant nozzles while providing continuous reinforcement across the affected pipe section.
How were the redundant nozzles incorporated into the repair?
The areas around the redundant nozzles were built up and smoothed using Belzona 1161, creating a suitable profile for the subsequent application of the Belzona SuperWrap II composite reinforcement.
What materials were used for the composite pipe repair?
The repair used Belzona 1161 (Super UW-Metal) to rebuild the pipe profile, followed by the Belzona SuperWrap II system, incorporating Belzona 1983 high-temperature resin and Belzona 9381 reinforcing fabric.
What was the outcome of the Belzona SuperWrap II repair?
The repair successfully reinforced and protected the deteriorated pipework while accommodating the redundant nozzles and complex geometry. The work was completed without replacing the affected pipe section.
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.
