Search Our Know-How in Action Case Studies

Date Created: 3/17/2024
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products: Belzona 1111 (Super Metal)
Problem : A cement ball mill was subjected to abrasions caused by the entrapment of cement particles under the mill tiles.

Industry: General Industry (GIND)  |  Application: SOS-Ships and Offshore Structures (SOS)  |  Products:

Belzona® 2311 (SR-Elastomer)

Problem : The uploading cement hose had worn through to the reinforcement wire.

Date Created: 5/30/2005
Industry: Cement (CMNT)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona® 1311 (Ceramic R-Metal).

Problem : Deeply worn shaft due to abrasion from cement - leading to potential bearing failure.

Date Created: 12/1/2007
Industry: Heating, Ventilation & Air Conditioning (HVAC)  |  Application: TCC-Tanks and Chemical Containment Areas (TCC)  |  Products:

Belzona® 4141 (Magma Build)

Belzona® 4181 (Magma AR Screed)

Problem : The system required a sump for the waste water to pass through, and having drilled it from solid concrete, it had to be lined and sealed.

Date Created: 12/14/2007
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona® 1812 (Ceramic Carbide FP)

Problem : Abrasion from the felt seal and limestone wore this major component of the mill.

Date Created: 5/16/2013
Industry: Power (POWR)  |  Application: VPF-Valves, Pipes and Fittings (VPF)  |  Products:

Belzona® 1221(Super E-Metal) Belzona® 1161(Super UW-Metal) Belzona® 5831(ST-Barrier)

Problem : The yellow phase bushing was leaking oil and the uncontrolled release required sealing to allow further planned maintenance of other transformers in t...

Date Created: 11/8/2013
Industry: Cement (CMNT)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona 1111 (Super Metal)

Belzona 9411 (Release Agent)

Problem : Worn pin bush housing of the loader

Date Created: 7/18/2016
Industry: Mining & Quarrying (MINQ)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona 1111 (Super Metal),

Belzona 1813

Belzona 9811

Problem : The hopper is situated on top of the machine and one section suffers from severe abrasion. Structural failures on that section would cause safety and ...

Date Created: 10/18/2017
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona 1811 (Ceramic Carbide)

Belzona 1812 (Ceramic Carbide FP)

Problem : Where the cement hits some areas of the blower they experienced severe abrasion and erosion. They required an alternative to welding fresh metal plate...

Date Created: 3/21/2019
Industry: Mining & Quarrying (MINQ)  |  Application: FBC-Fans, Blowers and Compressors (FBC)  |  Products:

Belzona 1812 (Ceramic Carbide FP)

Belzona 1321 (Ceramic S-Metal)

Problem : The dry air (70˚C) carrying Al, Si, MgO, CaO dust erodes the vanes of the fan blades, removing 2.5-3 mm fo thickness from the metal.

Date Created: 4/30/2019
Industry: Mining & Quarrying (MINQ)  |  Application: WPA-Wall Problem Areas (WPA)  |  Products:

Belzona 5111

Problem : Hot gases had led to corrosion on internal surface of filter chamber. The rough surface caused by corrosion allowed a build up of dust on surface.

Date Created: 6/12/2005
Industry: Cement (CMNT)  |  Application: TCC-Tanks and Chemical Containment Areas (TCC)  |  Products:

Belzona® 1111 (Super Metal)

Problem : Excessive wear under the steel tile of the roller due to failure of steel tile during operation.

Date Created: 12/22/2005
Industry: Cement (CMNT)  |  Application: SOS-Ships and Offshore Structures (SOS)  |  Products:

Belzona® 1221 (Super E-Metal)

Problem : Failure of the rubber gasket allowed cement to fall from the hopper when it was being emptied.

Date Created: 12/22/2005
Industry: General Industry (GIND)  |  Application: GSS-Gaskets, Seals and Shims (GSS)  |  Products:

Belzona® 2111 (D&A Hi-Build Elastomer)

Problem : Poor sealing between the steel gate and the valve housing meant that there was a 2-3 mm gap all around the seal area.

Date Created: 12/22/2005
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona® 4811 (Magma AR Screed)

Problem : Deterioration of the steel plates and steel seats due to wear from the cement bags.

Industry: Cement (CMNT)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona® 1111 (Super Metal)

Problem : Worn shaft due to bearing seizure.

Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona® 1111 (Super Metal)

Problem : Wear had occurred on the housing due to breakage of lining tiles which leads to direct impact of milling balls with barrel.

Industry: Cement (CMNT)  |  Application: ENC-Engines and Casings (ENC)  |  Products:

Belzona® 1111 (Super Metal)

Problem : Casings on trunnion supports shattered due to the breakage of the roller neck.

Industry: General Industry (GIND)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona® 1111 (Super Metal)

Belzona® 9411 (Release Agent)

Problem : Lubrication system failed and caused severe damage to bearing housing.

Date Created: 3/24/2008
Industry: General Industry (GIND)  |  Application: GSS-Gaskets, Seals and Shims (GSS)  |  Products: Belzona® 1812 (Ceramic Carbide FP)
Problem : The ingress of limestone particles into the 10-20mm gap between the tubular screw conveyor and its housing leads to wear and leakage of milling media ...

Date Created: 3/26/2008
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona® 4111 (Magma Quartz)

Belzona® 1121 (Super XL-Metal)

Problem : Wear on the shell when operating with missing protective tiles.

Date Created: 12/27/2009
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona® 1121 (Super XL-metal)

Problem : Wear on the casing needed to be rebuilt before the bolting of the new wear plates.

Date Created: 2/26/2010
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona® 1812 (Ceramic Carbide FP)

Belzona® 1321 (Ceramic S-Metal)

Problem : The auger screws suffer severe abrasion and client needed an effective protection system.

Date Created: 2/3/2012
Industry: Cement (CMNT)  |  Application: GSS-Gaskets, Seals and Shims (GSS)  |  Products:

Belzona 1321 (Ceramic S-Metal) Belzona 1812 (Ceramic Carbide FP)

Problem : Ingress of lime particles and water caused severe wear between feed screw insert andball mill journal. The diameter is 1500mm and length 200mm. 

Date Created: 2/3/2012
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona® 4111 (Magma Quartz)

Belzona® 1812 (Ceramic Carbide FP)

Belzona® 1121 (Super XL-Metal)

Problem : Severe wear particularly on the front wall and feed tube into the main shell.

Date Created: 7/24/2024
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products: Belzona 1311 (Ceramic R-Metal), Belzona 1391T, Belzona 1812 (Ceramic Carbide FP), Belzona 1813, Belzona 9811
Problem : The shell of separator suffers from severe abrasion and structural defects in that section would cause safety and operational problems.

Date Created: 3/20/2020
Industry: Cement (CMNT)  |  Application: WPA-Wall Problem Areas (WPA)  |  Products:

Belzona 5892

Problem : The temperature in the furnace bag filters has caused corrosion of the bag filter walls.

Date Created: 9/22/2013
Industry: (LOMU)  |  Application: WPA-Wall Problem Areas (WPA)  |  Products:

Belzona® 4141 (Magma Build)

Problem : The sandstone window frames and roof edges were corroded and cracked due to many years of weather damage

Date Created: 10/13/2011
Industry: Cement (CMNT)  |  Application: VPF-Valves, Pipes and Fittings (VPF)  |  Products:

Belzona® 1811 (Ceramic Carbide)

Problem : There was high abrasion caused by cement leading to local material loss of metal from valve body.

Date Created: 7/25/2019
Industry: Mining & Quarrying (MINQ)  |  Application: WPA-Wall Problem Areas (WPA)  |  Products:

Belzona 4111 (Magma Series)

Problem : During long-term operation under varying climatic conditions and high temperatures, the foundation (supports, beams) was degraded under the head of th...

Date Created: 2/5/2016
Industry: Buildings & Structures (BSTR)  |  Application: FPA-Floor Problem Areas (FPA)  |  Products:

Belzona 2911 (Elastomer QD Conditioner)

Belzona 2221 (MP Fluid Elastomer)

Problem : Gap in the expansion joint allowed room pressure to escape room below into this area, causing Air Handler performance to be inefficient. The gap was s...

Date Created: 8/2/2012
Industry: Power (POWR)  |  Application: VPF-Valves, Pipes and Fittings (VPF)  |  Products:

Belzona® 1291 (ES Metal)

Belzona® 1221 (Super E Metal)

Belzona® 1161 (Super UW Metal)

Belzona® 5831 (ST Barrier)

Problem : The red phase bushing was leaking oil and the uncontrolled release required sealing. The equipment is aged and the porcelain shed appeared to be fragi...

Date Created: 10/3/2015
Industry: General Industry (GIND)  |  Application: VPF-Valves, Pipes and Fittings (VPF)  |  Products:

Belzona 2311 (SR Elastomer)

Belzona 2911 (Elastomer QD Conditioner)

Problem : The customer uses a cyclone and piping to move cement from barges to silos. Eroded areas at the edge of the valve flappers were allowing small amount...

Date Created: 3/31/2008
Industry: Mining & Quarrying (MINQ)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona® 1111 (Super Metal)

Problem : A bearing spun on the rock crusher at the cement plants quarry. Without the crusher back in service the entire quarry and cement plant would shut down...

Date Created: 8/8/2012
Industry: Buildings & Structures (BSTR)  |  Application: WPA-Wall Problem Areas (WPA)  |  Products:

Belzona 4141 (Magma Build)

Belzona 5122 (Clear Cladding Concentrate)

Problem : The stone work was weathering and the brick work was dirty. In addition there were areas suffering from rainwater ingress.

Date Created: 7/22/2025
Industry: Buildings & Structures (BSTR)  |  Application: VPF-Valves, Pipes and Fittings (VPF)  |  Products: Belzona 1984, Belzona 4141 (Magma-Build), Belzona 4911 (Magma TX Conditioner)
Problem : During the refurbishment of an old piping system within a commercial building, the customer discovered an active leak at a lead and oakum joint. These...

Date Created: 7/14/2020
Industry: Buildings & Structures (BSTR)  |  Application: FPA-Floor Problem Areas (FPA)  |  Products:

Belzona 4111 (Magma Quartz)

Belzona 4911 (TX Conditioner)

Problem : Removing & replacing the paving slabs would have been a highly disruptive & costly undertaking. A durable & aesthetically pleasing repair solution was...

Date Created: 3/21/2024
Industry: Steel & Metal Processing (STEL)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products: Belzona 2111 (D & A Hi-Build Elastomer), Belzona 2311 (SR Elastomer)
Problem : The customer was suffering various issues on their conveyor belts. There were detachments in the area of the original tape bonding. There was signific...

Date Created: 9/16/2013
Industry: Buildings & Structures (BSTR)  |  Application: FPA-Floor Problem Areas (FPA)  |  Products:

Belzona 4131 (Magma-Screed)

Belzona 5811 (Immersion Grade)

Problem : Over time the movement of the balcony had caused cracks in the substrate. The client had previously tried sand and cement repairs which had failed due...

Date Created: 4/12/2019
Industry: Mining & Quarrying (MINQ)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona 1111 (Super Metal)

Problem : There are three rollers per mill and there are 12 wear plates (1200kg each) per roller. The clamps are fixed with 4 large bolts. There was play betwee...

Date Created: 1/6/2018
Industry: Food & Drink (FOOD)  |  Application: TCC-Tanks and Chemical Containment Areas (TCC)  |  Products:

Belzona 5811

Belzona 5111

Belzona 3921

Belzona 3111

Problem : The customer spent a great amount of money on a new cooling tower. They did not want to have problems in the future with framework and piping.

Date Created: 6/16/2008
Industry: Cement (CMNT)  |  Application: TCC-Tanks and Chemical Containment Areas (TCC)  |  Products:

Belzona® 1121 (Super XL Metal)

Belzona® 3921 (GSC Surface Conditioner)

Belzona® 5111 (Ceramic Cladding)

Problem : This is a very corrosive environment due to the nature of the raw material and the high temperatures used in the process led to serious corrosion on t...

Date Created: 5/13/2005
Industry: Buildings & Structures (BSTR)  |  Application: WPA-Wall Problem Areas (WPA)  |  Products:

Belzona® 4141 (Magma Build)

Problem : The concrete lintels had spalled revealing the reinforcement bars underneath. The Housing Association were fitting new windows and wanted repairs carr...

Date Created: 1/3/2006
Industry: General Industry (GIND)  |  Application: TCC-Tanks and Chemical Containment Areas (TCC)  |  Products:

Belzona® 5811 (Immersion Grade)

Problem : Poor adhesion of old non-Belzona coating.

Date Created: 6/14/2005
Industry: Cement (CMNT)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona® 1121 (Super XL-Metal)

Problem : Bearing area of the 155mm shaft was down due to bearing failure, causing the entire operation to shut down.

Date Created: 10/13/2017
Industry: Cement (CMNT)  |  Application: TCC-Tanks and Chemical Containment Areas (TCC)  |  Products:

Belzona 1111 (Supermetal)

Belzona 5811 (Immersion Grade) 

Problem : Any moisture ingress will ruin the stored materials. The customer had noticed problems and after inspecting found that the lid was severely corroded a...

Date Created: 7/18/2019
Industry: Cement (CMNT)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona 1111 (Super Metal)

Problem : Heavy wear had occured and required repairing before potential equipment failure.

Date Created: 1/7/2009
Industry: Cement (CMNT)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products: Belzona® 1111 (Super Metal)
Problem : Kilns were to be shut down in approximately 4-6 weeks but failed split bearing caused scoring of shaft requiring urgent repair.

Date Created: 4/29/2014
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona 1311 (Ceramic R-Metal)

Belzona 9811

Problem : Excessive wear on the flop gate (valve) made of AR steel (AR 400). It only lasted 9 months before wearing out. Customer was looking for a longer term ...

Date Created: 8/26/2014
Industry: Cement (CMNT)  |  Application: FPA-Floor Problem Areas (FPA)  |  Products:

Belzona 1811 (Ceramic Carbide)

Problem : The seating area of the diverter valve would wear.

Date Created: 9/19/2025
Industry: Mining & Quarrying (MINQ)  |  Application: VPF-Valves, Pipes and Fittings (VPF)  |  Products: Belzona 1161 (Super UW-Metal), Belzona 1984, Belzona SuperWrap II
Problem : A rubber-lined slurry pipe inside a cement plant has developed an approx 1-inch diameter hole that has penetrated through the wall, resulting in an ac...

Date Created: 7/26/2021
Industry: Mining & Quarrying (MINQ)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona 1121 (Super XL Metal)
Belzona 1812 (Ceramic Carbide FP)
Belzona 4111 (Magma-Quartz)
Belzona 4911 (Magma TX Conditioner)

Problem : In the mill there is a chamber for pre-drying with lift paddles. Under the paddles the wall eroded over years from cement dust (between 0 and 12mm). W...

Date Created: 3/16/2018
Industry: Buildings & Structures (BSTR)  |  Application: TCC-Tanks and Chemical Containment Areas (TCC)  |  Products:

Belzona 1111 (Supermetal) Belzona 5811 (Immersion Grade)

Problem : The customer had noticed problems with their cement storage silo and after inspecting found that the lid was severely corroded and was letting in rain...

Industry: General Industry (GIND)  |  Application: TCC-Tanks and Chemical Containment Areas (TCC)  |  Products:

Belzona® 3211 (Lagseal)

Problem : The Electrostatic precipitators at this large cement manufacturer operate at 70kv and 200°C (392°F). As a consequence they are insulated to conserve h...

Date Created: 2/17/2012
Industry: Buildings & Structures (BSTR)  |  Application: RPA-Roof Problem Areas (RPA)  |  Products:

Belzona® 3131 (WG Membrane)

Problem : Approximately 8 years prior to the Belzona application the corridor walkways had been enclosed to provide a safe and warm environment for children and...

Date Created: 12/31/2024
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products: Belzona 1812 (Ceramic Carbide FP), Belzona 4111 (Magma-Quartz), Belzona 4911 (Magma TX Conditioner)
Problem : Two rows of lifting liners (steel with welded wear layer) are mounted in the pre-drying chamber of the tube mill. Cement dust gets between the lifting...

Date Created: 5/12/2021
Industry: Cement (CMNT)  |  Application: FBC-Fans, Blowers and Compressors (FBC)  |  Products:

Belzona 1111 (SuperMetal)

Belzona 1812 (Ceramic Carbide FP)

Belzona 1818

Problem : High wear of the housing, pipes and cone fittings, caused by aggressive abrasion of various materials in the production process

Date Created: 4/20/2023
Industry: Marine (MRNE)  |  Application: SOS-Ships and Offshore Structures (SOS)  |  Products: Belzona 1121 (Super XL-Metal)
Problem : The USS Bowfin a Historical WWII Submarine had been situated in the Pearl Harbor Submarine Museum and Park since it was retired in 1971. After 20 year...

Date Created: 2/17/2012
Industry: Buildings & Structures (BSTR)  |  Application: FPA-Floor Problem Areas (FPA)  |  Products:

Belzona® 4131 (Magma Screed)

Problem : Some loose and damaged tiles had been removed in the playground bordering a class room. This had left concrete exposed and the area looking unsightly ...

Date Created: 9/23/2013
Industry: Buildings & Structures (BSTR)  |  Application: FPA-Floor Problem Areas (FPA)  |  Products:

Belzona 4131 (Magma Screed)

Problem : The stone steps on several staircases in this Grade 2 listed College had become badly worn over the last 500+ years of use and so were considered a He...

Date Created: 8/22/2012
Industry: Mining & Quarrying (MINQ)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona 1311 (Ceramic R-Metal)

Problem : Due to the nature of the operation, the internal surfaces of the ball mill are subject to constant impact from the falling balls and other media prese...

Date Created: 1/28/2008
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products:

Belzona® 1321 (Ceramic S-Metal)

Belzona® 9211 (Supergrip Agregate)

Problem : The drive roller had no lagging and was exposed to the weather conditions causing loss of grip and slippage.

Date Created: 8/30/2015
Industry: Mining & Quarrying (MINQ)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona 1111 (Super Metal)

Problem : The hammer crusher shaft was worn on the taper bearing location.

Date Created: 6/7/2016
Industry: Buildings & Structures (BSTR)  |  Application: WPA-Wall Problem Areas (WPA)  |  Products:

Belzona 4111 (Magma-Quartz)

Belzona 4154 (Bulkfill Resin)

Belzona 4911 (Magma TX Conditioner)

Problem : Severe cracks and damage in the walls of the ammonia secondary containment due to design issues.

Date Created: 10/18/2017
Industry: Cement (CMNT)  |  Application: VPF-Valves, Pipes and Fittings (VPF)  |  Products:

Belzona 1111 (Super Metal)

Problem : Whilst the system was offline, condensed gases created corrosion (deep 3 mm) on the DN 125 air pipe distributor.

Date Created: 1/17/2020
Industry: Cement (CMNT)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products: Belzona 1511 (Super HT-Metal)
Problem : The client was undertaking refurbishment works on one of their ball mills. During inspection it was highlighted that seven localised areas on a dome e...

Date Created: 11/20/2008
Industry: General Industry (GIND)  |  Application: RPA-Roof Problem Areas (RPA)  |  Products: Belzona® 3111 (Flexible Membrane)
Problem : Roof was leaking through the seams and joints.

Date Created: 7/10/2005
Industry: Marine (MRNE)  |  Application: SOS-Ships and Offshore Structures (SOS)  |  Products:

Belzona® 1121 (Super XL-Metal)

Problem : Pintle housing had become oversized due to corrosion.

Date Created: 1/3/2006
Industry: General Industry (GIND)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona® 1131 (Bearing Metal)

Problem : Severe wear due to dusty working environment.

Date Created: 1/3/2006
Industry: General Industry (GIND)  |  Application: HEX-Heat Exchangers (HEX)  |  Products:

Belzona® 1111 (Super Metal)

Belzona® 1321 (Ceramic S-Metal)

Problem : Holes and cracks had appeared on the end covers due to freezing water.

Date Created: 1/3/2006
Industry: Buildings & Structures (BSTR)  |  Application: TCC-Tanks and Chemical Containment Areas (TCC)  |  Products:

Belzona® 1221 (Super E-Metal)

Problem : A 700mm long crack had appeared on the weld joint of the steel walls

Industry: General Industry (GIND)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona® 1311 (Ceramic R-Metal)

Problem : Drive shaft was badly worn due to incorrect tightening of the adjustable sleeve which leads to relative motion between the shaft and the sleeve.

Industry: Cement (CMNT)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona® 1321 (Ceramic S-Metal)

Problem : Severe wear on these 230mm diameter shafts caused by extreme loads, vibration and abrasion from dust leads to bearing failure.

Industry: General Industry (GIND)  |  Application: SHM-Solids Handling Machinery (SHM)  |  Products: Belzona® 1812 (Ceramic Carbide FP)
Problem : Coal cyclone wears out fast due to abrasive action of coal particles at high velocity and temperatures of around 100°C.

Date Created: 7/30/2020
Industry: Cement (CMNT)  |  Application: MPT-Mechanical Power Transmission (MPT)  |  Products:

Belzona® 1111 (Super Metal)

Problem : The crusher rotor was damaged due to the loading and working environment.

Date Created: 3/8/2024
Industry: Buildings & Structures (BSTR)  |  Application: FPA-Floor Problem Areas (FPA)  |  Products: Belzona 4111 (Magma-Quartz), Belzona 4151 (Magma-Quartz Resin), Belzona 4911 (Magma TX Conditioner)
Problem : Due to repeated heavy vehicle and pedestrian traffic, damage to concrete joints and cracks in the floor are common in any industrial warehouse. These ...

Industry: Oil & Gas (OILG)  |  Application: GSS-Gaskets, Seals and Shims (GSS)  |  Products:

Belzona® 2311 (SR Elastomer)

Problem : Damage had been caused to the rubber on the sealing face of the male hose connector, due to contact with sharp metal edges on the female connector. As...