Emergency Belzona Repair on a 92" Circulation Pipe

KHIA ID: 10294
Industry: Power (POWR)
Application: VPF-Valves, Pipes and Fittings (VPF)
Substrate: Carbon steel
Customer Location: NE Oklahoma
Application Date: June 2026
Products: Belzona 1111 (Super Metal),Belzona 1982 (SuperWrap II),Belzona SuperWrap II
Problem: This 92" cooling tower circulation pipe had developed severe corrosion at ground level resulting in a 1"+ hole, as well as lesser corrosion all the way around. The customer was forced to shut down operations due to the size of the leak. This section of pipe is well supported, but where the corrosion was, is where it is set on the underground concrete portion of the system.

Original condition, including the biggest through-wall defect.

Abrasive blasting completed.

Belzona 1111 applied to the corroded area.

Belzona SuperWrap II system almost completely applied.

Application Situation
Replacing this 92" pipe was not an option, and with the level of corrosion, and the proximity of the concrete pipe, welding was not an option. Belzona 1111 was applied to the inside to seal the holes before a rubber liner was installed. The customer needed a fast solution that would allow them to resume operation in a short amount of time.
Application Method
The surface was abrasive blasted to the proper profile and Belzona 1111 was applied over the rough surface to smooth it out so the Belzona SuperWrap II could be applied properly. All the Belzona materials were applied using the tools provided with the materials.
Belzona Facts
The quick turnaround of a 24 hour cure after the application was completed was perfect for this emergency situation. There was no other alternative considered as Belzona has been a proven solution at this facility for several years, including many in-house application of the Belzona SuperWrap II system.
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