How to repair a live leak on a tank
A live tank leak can be repaired by sealing the leak with Belzona 9611 (ES Metal) and reinforcing it with a bonded plate using Belzona 1161.
Live leaks and through-wall defects present major safety concerns to asset owners. This video demonstrates how live leaks on tanks operating at low pressures can be stemmed effectively by using Belzona 9611 (ES Metal) and Belzona 1161.
Key Takeaways: Repair Method, Materials & Tools:
- Live tank leaks can be repaired without welding by using cold-applied epoxy systems
- The repair involves sealing the leak first, then reinforcing it with a bonded metal plate
- A rapid-curing epoxy Belzona 9611 (ES-Metal is used to stop active leaks quickly
A structural epoxy Belzona 1161 (Super UW-Metal) is then used to bond a plate for a permanent repair - The repair materials are corrosion-resistant and withstand a wide range of chemicals
- No specialist tools are required, and the material can be machined after curing
Follow these steps to repair a live tank leak:
STEP ONE:
Prepare the surface
Using a file, roughen the surface around the live leak area.
STEP TWO:
Prepare Belzona 9611
Knead Belzona 9611 to prepare it for stemming the live leak.
STEP THREE:
Apply Belzona 9611
Using a Belzona applicator, force the mixed material into the through-wall defect.
STEP FOUR:
Allow the product to cure
Using a 2″ x 4″ stud and a Ratchet strap, secure the material in place until it is fully cured.
STEP FIVE:
Remove once cured
Once cured (approx. 1 hour later), remove stud, strap and applicator.
STEP ONE:
Roughen application area
Using a grinder, machine down the cured material, and roughen the bond area to remove all existing coating and achieve the best profile possible.
STEP TWO:
Clean the repair area
Clean and degrease the bond area with Belzona 9111.
STEP THREE:
Mix Belzona 1161
Transfer the entire contents of Belzona 1161 Base and Solidifier onto a Belzona mixing board and mix thoroughly until a uniform color, free of any streakiness, is achieved.
STEP FOUR:
Apply Belzona 9111
Clean and degrease the bond surface of the preformed metal plate to remove all surface contaminants.
STEP FIVE:
Apply Belzona 1161 to Plate
Apply a thin layer of the mixed material onto the prepared preformed plate, pressing down firmly.
STEP SIX:
Apply Belzona 1161 onto Tank
Apply the mixed material directly onto the prepared surface, pressing down firmly to ensure maximum contact with the surface.
STEP SEVEN:
Form a build up
Form a build up approx. ¼” (6 mm) towards the center.
STEP EIGHT:
Position plate on tank
Push the plate into position, pressing firmly in the middle to push the material towards the outside. This will help prevent air entrapment.
STEP NINE:
Remove Excess
Remove excess material immediately. Chamfer the edges of the plate with the exuded Belzona 1161.
STEP TEN:
Remove Tape
Remove the tape. The application is complete.
Real-world examples of this repair method used in industry:
REPAIR OF A LIVE LEAK ON A DIESEL FUEL STORAGE TANK
Repair of a small live leak on a diesel tank using Belzona
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Frequently asked questions
Can a live tank leak be repaired without welding?
Yes. Low-pressure live tank leaks can be repaired using cold-applied epoxy composite systems such as Belzona 9611 and Belzona 1161, eliminating the need for hot work or welding. The leak is first sealed using a rapid-curing epoxy, then reinforced with a bonded metal plate for long-term structural integrity.
What products are used to repair a live tank leak?
This repair method uses Belzona 9611 (ES-Metal) to quickly stem the active leak and Belzona 1161 (Super UW-Metal) to bond and reinforce a metal plate over the damaged area. These materials provide excellent adhesion, chemical resistance and corrosion protection.
How long does a live leak repair take to cure?
Belzona 9611 typically cures in approximately one hour during the initial leak-stemming stage, depending on temperature and operating conditions. Once cured, the reinforcement plate can be bonded using Belzona 1161 to complete the permanent repair.
What surface preparation is required before repairing a tank leak?
Proper surface preparation is essential for long-term adhesion. The repair area should be roughened mechanically using a grinder or file, existing coatings removed, and the surface thoroughly cleaned and degreased using Belzona 9111 before applying the repair materials.
Can epoxy composite repairs withstand industrial chemicals and corrosion?
Yes. Belzona epoxy composite repair systems are designed for industrial environments and provide excellent resistance to corrosion, chemicals and environmental degradation. This makes them suitable for repairing tanks, pipes and process equipment operating in demanding conditions.
