External corrosion to pipe required a long term solution

KHIA ID: 9869
Industry: Water / Wastewater (WATR)
Application: VPF-Valves, Pipes and Fittings (VPF)
Substrate: Stainless-steel
Customer Location: Preston
Application Date: July 2025
Products: Belzona 1111 (Super Metal)
Problem: The high lift pumping station (HLPS) Delivery Water Main was situated within a culvert. Over time, a section of this main has thinned due to external corrosion. Originally, the wall thickness was believed to be 12mm, but the area at nozzle had reduced to approximately 7mm
An old corroded steel pipe

Pipe at nozzle was suffering from external corrosion

two steel plates next to the cleaned surface of the pipe, ready to be fitted around the nozzle

Cold applied plate bonding was selected as the long-term protection solution

The plate has been bonded around the nozzle with Belzona 1111 on the mixing board next to it

The pre-fabricated plate was fitted around the nozzle and loaded with Belzona 1111

Completed application of plate bonding over old corroded surface, with a smooth edged finish

Belzona 1111 was filleted, presenting a smooth finish and completing the long term protection solution

Application Situation
To prevent a through-wall defect, customer requested that the distributor propose a cold-bond solution to address the external corrosion, protect the pipe, and extend the asset's lifespan.
Application Method
The area was prepared using grinders and specialist surface preparation 110v powered tools.

Once the substrate was at an acceptable level, a prefabricated, rolled and blasted plate was dry fitted to the area, ensuring no adjustments were required.

Next, Belzona 1111 was applied directly to both the substrate and plate(s) using a stiff brush first to eliminate air entrapment. The plate(s) were then loaded with Belzona® 1111 in a manner to allow all material to evenly spread across the plate and substrate during bonding.

When all excess material had protruded from all 4 sides, Belzona 1111 product was filleted off the plate, leaving a smooth finish.
Belzona Facts
Plate bonding using Belzona 1111 restored integrity to the pipe and offered a long term solution to the external corrosion issue that the customer was facing
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