INDUSTRY
HVAC Systems
Repair composites and protective coatings for maintenance of HVAC systems
Heating, Ventilation and Air Conditioning
HVAC systems are often left unmaintained and put under enormous strain, particularly in summer and winter months. Lack of maintenance and treatment to control corrosion, erosion and microbiological growth can cause inefficient heat transfer, increased operational costs, reduced reliability and eventually, costly replacement.
Belzona Composite Repair Solutions
Belzona provides a variety of composite repair materials and protective coatings for the repair, maintenance and protection of HVAC equipment, inclusive of cooling towers, ductwork and chillers.
The key application areas of Belzona within HVAC include:
- Corrosion protection of internal surfaces
- Rebuilding and resurfacing of metallic surfaces
- Repair of mechanical elements such as shafts
- Protection of insulation and external surfaces
- Sealing of joints and seams
- Erosion protection of fan blades
Belzona Solutions Map for the HVAC industry is an interactive 3D map showing different sections of the HVAC machinery and equipment. The map serves as a tool that helps identify where repair and maintenance problems can occur and what solutions Belzona offers. Additionally, the map provides references to relevant case studies, includes photos and videos.
HVAC Solutions Map
HVAC APPLICATION
Chillers
Restoration and protection of chillers
Restoration and protection of chillers
Belzona’s metal repair materials are frequently used to repair chiller components, such as tube sheets, flange faces, water boxes and end covers, which are suffering from erosion and corrosion. These include Belzona 1111 (Super Metal), Belzona 1311 (Ceramic R-Metal) and Belzona 1121 (Super XL-Metal).
Additionally, Belzona offer high temperature resistant materials, such as Belzona 1511 (Super HT-Metal), that can be used to rebuild heat exchangers operating at temperatures up to 150°C (302°F).
Belzona epoxy coatings can be used to achieve long-term erosion and corrosion protection of chillers, including Belzona 1321 (Ceramic S-Metal), specifically designed to provide erosion resistance in continuous immersion at temperatures up to 60°C (140°F). For more information on heat exchanger repair and protection visit the application page..
CASE STUDIES
WIND POWER APPLICATION
Ductwork
General maintenance, repair and leak sealing
Solutions for the repair and protection of ductwork
Corrosion of ductwork can cause significant metal loss, leading to thin and even through-wall defects. Belzona’s metal repair materials offer a cold-applied alternative to replacement or unwanted hot work, allowing the metal to be rebuilt quickly, returning the ductwork to service with minimal downtime.
Moreover, failure of joints and seams can allow critical ingress of water and disruption of air flow, affecting the cooling and heating process. Belzona’s flexible repair materials, such as Belzona 2211 (MP Hi-Build Elastomer), offer a durable solution used to restore deteriorated joints and seams, whilst accommodating for movement. Similarly, Belzona 3121 (MR7) is a liquid-applied, flexible membrane, that is used in conjunction with HVAC systems on roofs and is ideal for sealing joints and emergency repairs.
To counteract the development of internal corrosion due to condensation or water ingress, internal air handler parts and ductwork can be coated. 100% solids internal coatings, such as Belzona 5811 (Immersion Grade), can be applied to prevent future corrosion, avoiding premature failure and replacement.
Finally, Belzona 3211 (Lagseal) can be used to encapsulate insulation, providing a barrier to moisture that can be cut open and resealed for periodic inspection. The liquid-applied, flexible membrane offers seamless protection of ductwork for a variety of complex contours, including elbows and T-pieces.
HVAC APPLICATION
Cooling Towers
Repair and protection of cooling towers
Repair and protection of cooling towers
Internal corrosion of cooling tower components can lead to severe metal loss and leaks on holding pans, diffuser trays and the framework itself. Coating of internal surfaces using Belzona 5811 (Immersion Grade) is a viable solution to eliminate the problem, offering high levels of corrosion and chemical resistance. This polymeric coating is designed to withstand the highly corrosive environment inside cooling towers.
Using Belzona 1212, a surface-tolerant epoxy composite, it is possible to plate bond onto wet or contaminated surfaces, ideal for leak sealing applications in holding pans or pipework. Moreover, any leaking seams and joints can be rectified with Belzona 3121 (MR7), which can be used in emergency situations without the need for surface primers or conditioners.
Fan blade leading edges are frequently damaged by impingement from moisture and dust particles, causing erosion-corrosion. Using Belzona 1311 (Ceramic R-Metal) the fan blades can be reformed before coating with Belzona 1341 (Supermetalglide), a long-term solution offering outstanding erosion and corrosion protection. In addition, fan shafts can be repaired using in-situ forming techniques alongside Belzona 1111 (Super Metal), returning the shaft to its original dimensions.
Cooling Tower Fan Blades
Fan blade leading edges are frequently damaged by impingement from moisture and dust particles, causing erosion-corrosion. Using Belzona 1311 (Ceramic R-Metal) the fan blades can be reformed before coating with Belzona 1341 (Supermetalglide), a long-term solution offering outstanding erosion and corrosion protection. In addition, fan shafts can be repaired using in-situ forming techniques alongside Belzona 1111 (Super Metal), returning the shaft to its original dimensions.
