Radiator End Cap Refurbishment

KHIA ID: 10153
Industry: Power (POWR)
Application: HEX-Heat Exchangers (HEX)
Substrate: Carbon steel
Customer Location: Auckland, New Zealand
Application Date: November 2025
Products: Belzona 5811DW (DW Immersion Grade)
Problem: The end caps were heavily corroded internally, and leakage at the sealing faces had led to reduced efficiency and the risk of damage to other systems.

This section shows the original condition of the end caps prior to refurbishment.

The surfaces were grit blasted to SSPC-SP10 or ISO Sa 2.5 in accordance with ISO 8501-1.

The surfaces were coated with two coats of Belzona 5811DW (DW Immersion Grade).

The end caps were fully reassembled with washers and are ready to be returned to service.

Application Situation
The radiator end caps were suffering from corrosion, which was affecting performance. Small leaks had begun to develop at the sealing faces, and the client was concerned that the heat exchanger could fail without immediate attention.
Application Method
After grit blasting, the internal faces were coated with two coats of Belzona 5811DW (DW Immersion Grade) to protect against future corrosion. New gaskets were manufactured and installed.
Belzona Facts
The alternative was to replace the heat exchanger, which would have resulted in an extended period of downtime and significant expense, both of which were unacceptable.
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