CASE STUDY
RAILWAY WATER TANK RESTORATION
Belzona restores heritage-listed railway water tank
Industry: Water & Wastewater – Heritage Restoration
Application: Repair and Restoration of Cracked and Damaged Water Tank
Products: Belzona 1121, Belzona 1161, Belzona 9341
Customer Location: : WA, Australia
Application Date: Sept, 2025
PROBLEM
The Merredin Railway Water Tower is a timber structure with a 25,000-gallon steel tank that supplied water to steam locomotives on the Eastern Railway.
For many decades, the tank built in 1911, has stood empty leaving it fully exposed to the elements. It has been continually subjected to tension and compression stress from temperature changes and flexural loads from wind and vibration from road and rail traffic.
In addition, severe corrosion and subsequent expansion of the carbon-steel packer plates at wall panel joints has caused major cracking.
Water tank after restoration, with fresh paint and a new roof
Structural cracking in the corners, wall panels and floor panels was extensive, with parts of the tank breaking away and some sections entirely missing.
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APPLICATION
Restoration works not only repaired the damage but also reduced the risk of future failures by modifying and strengthening key elements.
For the majority of the restoration works, the proposed solution was cold metal stitching. The stitching process involved drilling holes in the material in a line across the crack and also perpendicular to the crack, then installing overlapping stud screws to completely fill the crack.
Cracked wall joints were stitched and sealed using Belzona 1121. The repair was further reinforced with Belzona 9341 and light-gauge wire mesh.
Countersunk drill holes were carried out in preparation for securing the plate stitching
Stitching plates were fixed in place over cracks that were filled with Belzona 1121
Shaft former made to the exact specifications of the original shaft
A large corner piece that had broken away was recovered, temporarily supported, and stitching plates were positioned for fitment. Thereafter, the crack was filled with Belzona 1121, and the stitching plates were then bonded and screwed into the plates. The large corner section was then overcoated and reinforced with additional Belzona 1121.
Some floor and wall cracks were reinforced with light gauge reinforcement mesh. The reinforced areas were then covered, sealed and reinforced with Belzona 1121.
Corner cracks were rebuilt, sealed and given a smooth, flush external finish.
OUTCOME
Thanks to Belzona, the restoration has successfully returned the tank to a safe, stable condition while preserving its heritage character, ensuring it remains a valued landmark for both the local community and visitors.
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 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.
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.
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