CASE STUDY
LARGE-SCALE SPLIT CASE PUMP REPAIR
Repair of a 36″ vertical split case pump
Industry: Water & Wastewater
Application: Split Case Pump Repair
Products: Belzona 1111, Belzona 1341, Belzona 1812
Customer Location: : VIC, Australia
Application Date: 2025
PROBLEM
A water industry customer’s 36″ vertical split case pump had experienced significant wear, corrosion, and mechanical degradation across its internal and external components.
Key issues included pitting and erosion of casing internals, impeller, damaged seal water galleries, worn bearing and sealing surfaces and degraded wear rings.
Additionally, the scale and weight of the equipment introduced complex logistical and safety challenges, including disassembly, transport, lifting, and reinstallation of large components.
A comprehensive repair and refurbishment solution was required to restore the pump to its original operating condition, improve efficiency, and provide long-term erosion and corrosion protection.
Repaired and coated split case pump casing
APPLICATION
The application required restoring severely worn internal components, improving hydraulic efficiency, and ensuring long-term protection against erosion and corrosion.
The repair process began with onsite disassembly, followed by abrasive blasting of the pump casings and impeller to prepare all internal surfaces. Damaged and pitted areas across the casings, impeller, seal water galleries, and stuffing box were rebuilt using Belzona 1111 (Super Metal), while high-wear zones such as the cutwater were reinforced with Belzona 1812 (Ceramic Carbide FP).
To enhance efficiency and provide long-term surface protection, two coats of Belzona 1341 (Supermetalglide) were applied across all internal surfaces, including seal water galleries, achieving a total dry film thickness of approximately 500 microns.
Rebuilding pitted and worn areas with Belzona 1111 (Super Metal)
Front casing before repair
Front casing after blasting
First coat of Belzona 1341 (Grey) applied
Second coat of Belzona 1341 (Blue) applied
More Information?
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Mechanical restoration included machining and replacement of critical components such as wear rings, bearing sleeves, gland packing sleeves, and bushings, followed by balancing of the rotating assembly to G2.5 standard.
Due to the scale of the equipment, the application also involved complex lifting and transport activities, including removal and haulage.
Machining of wear rings
Rebuilding of worn areas on impeller with
Belzona1111 (Super Metal)
Worn areas on impeller rebuilt with Belzona 1111
First coat of Belzona 1341 (Supermetalglide) applied
Second coat of Belzona 1341 (Supermetalglide) applied
Shaft assembled on repaired and coated impeller
Transportation of split case pump components
Split case pump casing
Onsite reassembly of split case pump components
OUTCOME
The split case pump was successfully restored to reliable operating condition, with all with worn components rebuilt and key surfaces restored.
The pump was then reassembled with new sealing components and commissioned, returning the unit to reliable operation with improved performance and efficiency.
Protective Belzona coatings were also successfully applied to improve resistance to erosion and corrosion while enhancing hydraulic efficiency.
Despite the complexity of the works, all activities were completed safely and efficiently by the Rezitech Services Workshop team.
Shaft former fitted to the shaft and fixed in position
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.
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.
Belzona 1812 (Ceramic Carbide FP)
A 2-part epoxy-based composite material combining extremely hard closely packed abrasion resistant ceramic aggregates in a polymeric binder for the repair and protection of equipment damaged by fine particle abrasion.
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.
