CASE STUDY
COLD BONDING OF STEEL BRACKETS
Attachment of steel brackets to chemical tanks using Belzona 1511
Industry: Petrochemical
Application: Cold bonding of steel brackets
Products: Belzona 1511 (Super HT-Metal)
Customer Location: WA, Australia
Application Date: Mar 2023
PROBLEM
A chemical manufacturing company required a solution to securely attach over 350 steel brackets to 12 chemical tanks containing highly flammable liquids. These brackets were essential to support stainless steel pipes which form part of a new fire water sprinkler system installed on the top and the sides of the tanks.
Welding was not an option as the tanks were filled with chemicals. Emptying and preparing them for welding would have been a lengthy and costly process, potentially taking years.
As a result, the customer required a safe and proven cold bonding solution to attach the brackets efficiently and safely.
Steel bracket cold-bonded to chemical tank and load-tested to 132 Kgs
APPLICATION
Since the sprinkler system needs to function reliably in the event of a fire, Belzona 1511 (Super HT Metal), a high-temperature repair system suitable for applications up to 170 °C, was chosen as the cold bonding solution.
First, all surfaces were prepared by abrasive blasting, achieving SA 2.5 with a minimum profile of 75 microns. Belzona 1511 was then applied to both the brackets and the tank shell. Each bracket was positioned using a jig, which was tightened to ensure alignment, remove any excess bonding material and ensure an integral bond.
To complete the installation, a 45° fillet edge was applied around the base of each bracket for added strength and durability. The Brackets were allowed to cure for 30 hours at a temperature of between 25° – 30°C before being coated with a protective top coat.
Belzona 1511 applied to steel bracket
Application completed with a 45° fillet edge around the plate
OUTCOME
A load testing rig was set up to evaluate each bracket’s performance. The brackets were subjected to a load of 130 Kg and monitored for one hour, during which no failures occurred.
Belzona 1511 offered a simple cold bonding alternative to welding, providing the customer with a cost-effective solution to install a fire water sprinkler system without any disruptions to their manufacturing processes.
Load tester under tension
Completed tank showing shell ring pipe and vertical riser pipe
Fire water sprinkler system supported by cold-bonded steel brackets
Products
Belzona 1511 (Super HT Metal)
A two-part repair composite based on a solvent-free epoxy resin reinforced silicon with steel alloy. This high temperature repair system is designed for metal repair and rebuilding equipment and provides excellent corrosion protection.
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: HVAC, Oil and Gas, Mining, Power, Water and Wastewater, Pulp and Paper, Marine, and Manufacturing among others.
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We value growth and innovation within the maintenance solutions industry
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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!
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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.
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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.
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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.
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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.
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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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