Cooling Tower Lifeline

KHIA ID: 9778
Industry: Heating, Ventilation & Air Conditioning (HVAC)
Application: HEX-Heat Exchangers (HEX)
Substrate: Carbon steel
Customer Location: De Soto, Kansas
Application Date: March 2025
Products: Belzona 1121 (Super XL-Metal),Belzona 5811 (Immersion Grade)
Problem: These towers were reaching the end of their life cycle, there was large holes above the liner and several small pinhole leaks throughout the entire water basin. Without treatment, they would need to be replaced soon.

After sandblasting it became very apparent of the extent of the damage and the areas that needed to be focused on.

You can see the areas that had been complete rusted through.

Repairs were made to make the surface whole again.

After two coats of Belzona 5811 this tower was ready for many more years of service.

Application Situation
Belzona was able to not only repair the severely damaged areas, but also re-line the water basin. This process has extended the life of these towers by several years, allowing the customer to save significant money on replacement. This will also allow additional maintenance for this coating system, meaning that the life of the towers can be extended again in the future.
Application Method
The old fill was removed in preparation for the Belzona coating. This ensured access to the entirety of the cold-water basin. The entire surface was grit blasted, and all severely damaged areas were treated with sheet metal and Belzona 1121 to regain structure for coating. This was immediately followed by a coat of Belzona 5811. The second coat of Belzona 5811 was applied the following day. Afterwords a thorough inspection and touch up process took place to ensure that all areas were protected and sealed. New fill was replaced, and the tower was returned to service!
Belzona Facts
Cheaper and faster than replacement. No more loss of water from leaks. Easier to inspect and identify problems in the future. Repairable system installed means that this project can be revisited and extended again down the road.
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