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Belzona® Stops Live Air Handler Leak



Heating, Ventilation & Air Conditioning (HVAC)



Roof Problem Areas (RPA)


Customer Location:

Hospital, Nashville, TN, USA


Application Date:

September 2015


Application Situation:

Leaking air handler condensate pan.



The air handler condensate pan was leaking water. Corrosion had allowed for water to push underneath the pan and out between the pan and concrete pedestal. This was the result of a previously applied competitor's coating in the pan and around the bottom seam disbonding.



Belzona 3121 (MR7)



Galvanized Sheet Metal and Concrete


Application Method:

The application was carried out in accordance with a modified version of Belzona Know-How System Leaflet RPA-1. The areas in which the competitors coating had failed were scraped and cut away and the surface was cleaned using a reciprocating wire brush and acetone. The area was dried as well as possible but water was still escaping from under the pan and across the area to be repaired. Because of the presence of water, Belzona 3121 was chosen for it's surface tolerant properties. The joint where the water was leaking between the pan and the pedestal was then coated with Belzona 3121 to stop the water. The first application stopped most of the water but a second application/overcoat was needed to finalize it.


Belzona Facts:

The air handle pan could not be replaced without removing a wall of filter and supports. Contractors had estimated the removal and replacement of these to be nearly $500,000. While the air handler is approaching the end of it's service life, the hospital needed a way to keep it in service for several more years and keep water from draining onto the floor and allowing mold to grow in the room. It was not possible to take the air handler out of service for an extended period of time and a material that could be used in the presence of water and stop the leak quickly was needed. Belzona was the material that could handle the requirements.


Photographs Description

  1. Old coating disbonded, notice the bubble pushing through when the material was pressed on
  2. Bad portion of old coating removed, prepped with wire brush and wiped with acetone
  3. Application of Belzona 3121 in progress
  4. Completed application
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