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Belzona® Repairs 42 Bar Active Gas Leak



General Industry (GIND)



Valves, Pipes and Fittings (VPF)


Customer Location:



Application Date:



Application Situation:

Fertilizer plant gas leak was causing health and safety problems.



Natural gas active leak has developed and their safety department was about to shut down the plant to repair this dangerous leakage. This gas leak was also causing a loss in pressure to the rest of the plant, reducing efficiency and output.



Belzona 9611

Belzona 1111 (Super Metal)



Steel pipe


Application Method:

Belzona 9611 was applied into the immediate leak area with a clamp to hold it in place during curing. The application was carried out by 7 technicians at the same time due to the limited curing time in accordance with Belzona System Leaflet VPF-11. The pipe was then reinforced with Belzona 1111 to complete the repair.


Belzona Facts:

The only alternative to the Belzona solution would have been to shut down the plant, as this vessel was reducing gas pressure for the whole plant. A shutdown would have cost millions in lost production, so it was critical to keep the plant running. Conventional welding repairs were not an option due to the gas leak. Due to the good ongoing relationship the customer, they wanted to try a cold-curing repair which worked exceptionally well. The application duration was one working day and they inspected the repair by a gas detector device. The distributor had been working with this customer for 15 years and carried out many successful applications including: leak sealing, process vessel lining, pump repair, heat exchanger repair and coating. This customer’s maintenance team also use Belzona for their day-to-day maintenance applications.


Photographs Description

1 - Pressure gauge on pipe showing 42 bar

2 - Belzona 9611 clamped down on the repair

3 - The application of Belzona 1111 underway

4 - Work Complete

Case study pic one


 Case study pic two


 Case study pic three


 Case study pic four


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