CASE STUDY
BUTTERFLY VALVE REPAIR AND COAT
Repair and restoration of 84” butterfly valve
Industry: Power
Application: Valve repair
Products: Belzona 1121, Belzona 1341
Customer Location: : NSW, Australia
Application Date: June 2025
PROBLEM
A power industry client had an 84” butterfly valve that, after years of service and saltwater exposure, suffered severe erosion, corrosion and wear.
The internal surfaces of the valve body and disc were badly damaged, with holes through the body. The valve was due to be discarded, and the initial plan was to purchase a new butterfly valve at a huge cost.
BEFORE: Condition of the valve before repairs
AFTER: Butterfly valve after restoration
APPLICATION
Following an inspection by Rezitech Services, it was decided to refurbish the butterfly valve instead of replacing it.
First, the worn areas were abrasive blasted to remove degraded material and prepare the surface. Thereafter, the damaged areas were rebuilt and repaired using Belzona 1121 in three stages.
Once the profile was restored, two coats of Belzona 1341 were applied to all internal surfaces to provide erosion and corrosion protection.
New bearings also had to be machined and installed. In addition, all taper pins had to be removed and replacement pins were machined and installed.
Finally, the valve was reassembled and checked to confirm sealing integrity before the external surfaces were coated with Jotamastic 90.
Valve body in the abrasive blasting booth
Valve internals after abrasive blasting
Abrasive blasted disc showing severe erosion
Rebuilding of worn areas with Belzona 1121
First coat of Belzona 1341 applied
Second coat of Belzona 1341 applied
More Information?
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Condition of the valve internals after abrasive blasting
Damaged and corroded valve internals prior to repairs
Valve internals being rebuilt with Belzona 1121
Daily inspections were carried out on rebuilt areas
Valve internals were rebuilt with Belzona 1121 in three stages
First coat of Belzona 1341 applied
Second coat of Belzona 1341 applied
Valve internals were rebuilt with Belzona 1121 in three stages
Worn valve bearing being repaired using Belzona 1121
Repaired bearing bore with bearing replaced
New taper pins installed and sealed
OUTCOME
All refurbishment works were completed by the Rezitech Services workshop team in Hallam, Victoria.
With a fully equipped facility, Rezitech can deliver complete valve refurbishments in-house, producing repaired valves that last twice as long as new uncoated cast iron valves.
The application of Belzona 1341 also helps protect the seal seats from premature failure, further extending service life. The repair was delivered at a fraction of the cost of replacement, providing substantial savings in both cost and downtime compared to purchasing a new valve of a similar size.
The client was highly satisfied with the outcome and has since committed to sending two additional valves to Rezitech Services for repairs.
Completed valve repair with externals coated with Jotamastic 90
Products
Belzona 1121 (Super XL-Metal)
A 2-part repair composite for metal repair and resurfacing based on solvent-free epoxy resin reinforced with silicon steel alloy.
This repair material has been developed to offer an extended working life, ideal for large applications where greater volumes of material are required or to provide adequate working time at higher temperatures.
Belzona 1341 (Supermetalglide)
A 2-part epoxy coating designed to improve efficiency of pumps, pipes, valves and other fluid handling equipment while protecting them from the effects of erosion and corrosion. This high performance product is proven to reduce energy consumption, provide excellent chemical resistance and lower maintenance costs.
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.
