CASE STUDY
CORRODED WELD JOINTS REPAIR
Repair of corroded sand filter vessel weld joints
Industry: Mining
Application: Repair of corroded weld joints
Products: Belzona 1111, Belzona 9341, Belzona 5831, Belzona SuperWrap II, ReziSafe R230
Customer Location: : WA, Australia
Application Date: Nov 2024
PROBLEM
A mining customer required a solution to repair corroded weld joints in a sand filter vessel. Multiple holes were found on the weld joints and in other locations on the vessel.
The sand filter, constructed from 316L stainless steel, was exposed to raw water containing an average chlorine concentration of 1172.9 mg/L with a minimum level of 778.5 mg/L chlorine and an unknown level of microorganisms. Microbial corrosion was suspected as the cause of the damage.
Internal corrosion
External corrosion
APPLICATION
All internal and external weld joints were thoroughly prepared using abrasive blasting and comprehensively sealed with a combination of Belzona 1111 and Belzona SuperWrap II.
Filter tank surface preparation – Internal and external surfaces for the top and middle sections, and the external surface for the bottom section.
Cold repair – Stage 1 – Holes and cavities were filled on the internal and external surfaces of the top and middle sections, along with the external surface of the bottom section.
Cold repair – Stage 2 – A composite patch method was applied to reinforce the internal surfaces of the top and middle sections.
Internal areas blasted
Internal completed with a final coat of Belzona 5831
Filling deep pitting with Belzona 1111
SuperWrap II, Belzona 1111 and Belzona 9341 on different joints
External blasted and pits filled ready for SuperWrap II application
SuperWrap II being applied and rolled for compression
Completed SuperWrap II application
External completed with a final coat of ReziSafe R230 for UV protection
OUTCOME
The work was successfully completed and the tank filled to test for leaks, revealing only two minor leaks unrelated to the work performed.
More Information?
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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 5831
A 2-part epoxy coating which once cured forms a barrier coating for the protection of equipment operating under immersed conditions or in contact with aqueous solutions. This solvent-free epoxy coating bonds strongly to steel and other metallic and non-metallic surfaces such as concrete or brick.
Belzona SuperWrap II
Composite repair system for restoring the strength of holed, weakened and corroded pipe and tank walls. Carbon fibre and fibre glass repair system designed and applied in accordance with ISO24817 and ASME PCC-2 standards.
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.
