Belzona Super Wrap II saves a severely corroded manifold

KHIA ID: 10325

Industry: Food & Drink (FOOD)
Application: VPF-Valves, Pipes and Fittings (VPF)
Substrate: Carbon steel

Customer Location: Germany
Application Date: January 2026

Products: Belzona 1511 (Super HT-Metal),Belzona 1983 (SuperWrap II),Belzona 9111 (Cleaner Degreaser)

Problem: The manifold was insulated but had not been inspected for many years. During an inspection, severe corrosion was discovered, with deep pitting in several areas and even through-wall holes that were causing water leaks. An urgent repair was required to stop the leaks, restore the strength of the manifold, and provide long-term protection.

Corroded manifold

Substrate repaired using Belzona paste-grade materials

Start of the Super Wrap II application

Completed repair

Application Situation

The manifold had suffered severe corrosion damage, resulting in small holes and a significant reduction in the remaining wall thickness. A particular challenge was that the caustic tank was connected to the same system. The system could only be shut down for 2 to 3 hours, as the caustic solution would solidify at temperatures below 12°C. This made the repair especially demanding, as the source of the leaks had to be identified and repaired quickly to avoid an unplanned shutdown.

Application Method

To ensure a safe working environment, the area was first cordoned off with red-and-white safety tape. During the preparation stage, the surface was treated to achieve optimum adhesion and then cleaned with Belzona 9111.

The substrate was then repaired using Belzona 1511 in combination with Belzona 9341, which was used to seal the holes and rebuild the damaged areas. Once the substrate had been restored, the entire manifold was wrapped and reinforced with Belzona Super Wrap II. The repair was then consolidated using Belzona 9382, resulting in a fully sealed and long-lasting repair after curing.

Belzona Facts

Belzona provided a cost-effective repair solution with minimal downtime, allowing the severe corrosion damage on the manifold to be addressed quickly and efficiently. The Super Wrap II system restored the manifold’s structural integrity and significantly extended its service life.

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