Cooling Tower Base Corrosion Repair and Protection

KHIA ID: 10358
Industry: Heating, Ventilation & Air Conditioning (HVAC)
Application: HEX-Heat Exchangers (HEX)
Substrate: Carbon steel
Customer Location: Maitland, Florida
Application Date: July 2026
Products: Belzona 1161 (Super UW-Metal),Belzona 5111 (Ceramic Cladding),Belzona 5811 (Immersion Grade)
Problem: The steel base and supporting structure of the cooling tower showed extensive corrosion and severe deterioration of the existing protective coating. In several areas, corrosion had progressed to localized metal loss and significant surface damage. The customer required the affected structure to be restored and protected to prevent further deterioration while keeping the existing cooling tower support structure in service.
Cooling tower base support showing old coating on the upper section and coating removal with surface preparation in progress on the lower section.

Old coating visible on the upper section of the cooling tower base support, while surface preparation is underway on the lower section, showing removal of the deteriorated coating prior to application of the Belzona repair and protection system.

Localized pitting and corrosion damage on the cooling tower support beam before Belzona 1161 repair.

Close-up of severe pitting and corrosion on the cooling tower support beam before rebuilding with Belzona 1161.

Cooling tower support beam rebuilt with Belzona 1161 before protective coating application.

Belzona 1161 applied to rebuild and restore the pitted areas of the cooling tower support beam after mechanical surface preparation, prior to application of the final protective coating system.

Completed cooling tower base rehabilitation with Belzona 1161, 5811, and white 5111 topcoat.

Completed cooling tower base rehabilitation using Belzona 1161, Belzona 5811, and a final white coat of Belzona 5111 to restore and protect the existing steel support structure.

Application Situation
The objective was to rehabilitate the existing cooling tower base rather than replace the affected steel structure. Localized areas with significant corrosion damage required rebuilding, while the complete prepared surface needed a new corrosion protection system. The Belzona solution allowed the existing structure to be repaired in place and protected against continued environmental exposure.
Application Method
The deteriorated coating, loose corrosion, and surface contamination were removed using mechanical surface preparation equipment, including MBX and other mechanical tools, to expose sound steel and create the required surface profile. Belzona 1161 was used where necessary to rebuild localized areas affected by metal loss. One coat of Belzona 5811 was then applied over the prepared steel, followed by one coat of white Belzona 5111 as the final protective topcoat.
Belzona Facts
Belzona 1161 allowed localized corrosion damage and metal loss to be rebuilt without replacing sections of the cooling tower base. Belzona 5811 provided corrosion protection over the prepared steel structure, while Belzona 5111 was applied as the final white topcoat for additional environmental protection. The complete system restored and protected the existing cooling tower base while avoiding major structural replacement.
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