Belzona Repairs a Corroded Flange at a Gas Yard

KHIA ID: 10255
Industry: Oil & Gas (OILG)
Application: VPF-Valves, Pipes and Fittings (VPF)
Substrate: Carbon steel
Customer Location: Auckland
Application Date: April 2026
Products: Belzona 1111 (Super Metal)
Problem: During routine maintenance, a section of pipe (originally under insulation) was found to be severely corroded, with the flange particularly affected. The client determined that the best course of action was to seal the pitting and the flange boundary using Belzona as a temporary measure until the next shutdown.

The flange was severely corroded, requiring the bolts to be cut out for disassembly.

Grit blasting of the pipework was carried out and took most of the morning.

Once blasted, the flange was found to be in satisfactory condition, and the client decided to carry out a temporary repair using Belzona 1111 (Super Metal) until the next major maintenance shutdown.

Condition of the flange boundary after sealing with Belzona 1111 (Super Metal).

Application Situation
To prolong the service life of the assets, cladding and insulation are periodically removed for blast cleaning and repainting. When corrosion encountered during these maintenance activities is advanced, it may be necessary to first rebuild the pitted areas. In the past, the client used various epoxy materials with mixed results; however, none performed as effectively as Belzona. It has now become their preferred solution for reclaiming pitting corrosion, sealing leaks, and occasionally providing thermal protection in and around the gas yard.
Application Method
After blast cleaning, the asset is inspected and the metal thickness is assessed. Belzona 1111 (Super Metal) is then used to restore the original geometry of the flange and seal the boundary. This ensures that the asset can be repainted and returned to service without the need for replacement.
Belzona Facts
Full maintenance shutdowns are rare and extremely costly for the client, while regular maintenance windows are limited to just two days, making large-scale projects impractical. Belzona solutions provide rapid return to service and effective extension of asset life, having been tried and tested over many years at the site.
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