CASE STUDY
HYDRO POWER STATION SHAFT REPAIR
In-situ repair of a damaged shaft using Belzona
Industry: Hydroelectric Power
Application: Damaged Shaft Repair
Products: Belzona 1111
Customer Location: : VIC, Australia
Application Date: Sept 2025
PROBLEM
A shaft in a hydroelectric power station was damaged by a spun bearing, leading to a reduction in the turbine generator efficiency, diminished reliability, and possible risk of failure.
An in-situ repair solution was required, as removing and replacing the shaft was not feasible due to the labor-intensive, time-consuming, and costly nature of the process.
The shaft bearing housing inside a hydroelectric turbine assembly
APPLICATION
Belzona 1111 (Super Metal) was selected for the shaft repair due to its high compressive strength, excellent adhesion, and superior machinability.
First, the damaged shaft was rebuilt with Belzona 1111 using a forming technique as specified in Belzona system leaflet MPT-2. Once the Belzona 1111 was fully cured, an in-situ machining technique was used to restore the shaft to its original dimensions.
Shaft damaged by a spun bearing
Damaged shaft rebuilt with Belzona 1111
Shaft machined to its original dimensions
OUTCOME
The customer successfully completed the repair, refitted the bearing and returned the unit to service without the cost, effort, or downtime typically associated with a full shaft replacement.
More Information?
For more information about the Rezitech products and services, fill out the form below and one of our staff members will be in touch in 1-2 days.
Products
Belzona 1111 (Super 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 will not corrode and resists a wide range of chemicals. It is easy to mix and apply without the need of specialist tools and can be machined using conventional tools.
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.
