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- 2. Founded 1952 Unmatched Technical Service Alternative to Conventional Repairs High Performance Polymers About Belzona Belzona Headquarters in Harrogate, UK Belzona Headquarters in Miami, USA Global Network in 150 Countries
- 3. QUALITY 9002 Certified - # Q09335 In House Manufacture Quality and Consistency Assured EXPERIENCE A Half Century of Experience Belzona® “Know-How” Systems Industry Wide Approvals SUPPORT Local Service Factory Trained Consultants / Contractors Technical Assistance 24 hours, 7 days a week About Belzona
- 4. Belzona Metallic Polymers Belzona Barrier Polymers Belzona Magma Polymers Belzona Polymeric Membranes Belzona Elastomeric Polymers Belzona Polymer Systems About Belzona
- 5. Impeller Rescued From Scrap Pile Completely Refurbished With Belzona 1000 Series Products Pump
- 6. Suction Bell Severely Eroded Replacement: $ 8,000 in 6 weeks Repaired With Belzona 1000 Series Product For Only $ 1,200 Within Two Days Pump
- 7. Eroded Casing Rebuilt With Belzona Paste Grade Metal After Checking Clearance, Belzona Coatings Applied For Additional Protection Pump
- 8. Sludge Pump Backing Plate Severely Eroded, Refurbished With Belzona 1000 Series Ceramic Materials New Impeller Protected With Belzona Pump
- 9. Sludge Pump Casing Badly Abraded Rebuilt and Protected using Belzona Erosion / Corrosion Resistant System Pump
- 10. Gorman Rupp Sludge Pump Eroded & Impeller Stuck These Used to Be Scrapped & Cost $6,500 for Replacement Casing & Impeller Rebuilt & Coated With Belzona Wear Resistant Products A Complete Belzona Refurbishment Only Cost $1,000 Pump
- 11. Wemco-Muniflo Rotary Lobes Damaged by Solid Abrasion A Perfect Mould Is Made From a New Lobe Using Belzona Forming Technique Lobe Pump
- 12. New Lobe Casted With Belzona Fluid Elastomer Inspection After 1 Year Shows No Wear Lobe Pump
- 13. Acid and Hydrogen Sulfide Attacked at the Liquid / Gas Interface Causing Premature Failure of the Sewerage System. Concrete Surfaces Sealed With a Belzona 4000 Magma Product by Spraying Concrete
- 14. Clarifier Drained for Renovation Obvious Damages To the Trough Concrete Due to Failure of Coal Tar Epoxy Coating Concrete
- 15. Trough Concrete Rebuilt With Belzona 4000 Series Products & Coated With Belzona Immersion Grade Concrete
- 16. The Skimmer in Operation Rolling Over the Concrete Rail The Concrete Rail Completely Repaired With Belzona 4000 Series Products Concrete
- 17. Concrete Hand Rail Post Spalled, Regular Concrete Repairs Failed Quickly Permanently Fixed With Belzona 4000 Series Products Concrete
- 18. Oxygen Aeration Tank Cracked, Loosing Oxygen & Pressure Metal Plate Fastened Up As a Former Belzona 4000 Series Materials Poured Into the Gap Leakage
- 19. Empty Clarifier The Expansion Joint Showing Failed Previous Elastomeric Sealant Re-Sealed With Belzona 3000 Series Flexible Product Leakage
- 20. Failed Previous Coatings Allowed Digester Floating Dome to Deteriorate, A Long Term Solution Needed for Protection & Safety Concerns High Performance Belzona Flexible Water Proofing Coatings Applied to the Entire Dome Metal Surface Leakage
- 21. Stainless Steel Grit Separator Was Abraded & Eroded Replacment Unit Would Have Cost $6,000 All Interior Surfaces Were Coated With Belzona 1000 Series Wear Resistant Products Only Cost About $1000 & Including Labor Mechanical Damage
- 22. Badly deteriorated Trickling Filter Pedestal Replacement delivery - 8 Months Repaired in Place With Belzona Forming Technique The Plant Realized No Need to Order a Costly Replacement Mechanical Damage
- 23. Worn Out Micro Screen Shaft Dismantling Shaft for Replacement Is Not Acceptable Repaired in-situ, using Belzona Sleeve Bonding Technique. Mechanical Damage
- 24. How Agitator Propellers Look Like After One Year in Service Replacement of 7 Propellers Would Have Cost $3,500 How a Belzona Protected Propeller Looks Like After One Year in Service Mechanical Damage
- 25. Repairs Has Been Done Four Times With Belzona 1000 Series Products 7 Propellers With Belzona Protection Only Cost $300 Mechanical Damage
- 26. Mechanical Damage Convenient in house shaft repairs, saving Time, Money & Inconvenience.
- 27. Rubber Lining on BIRD Centrifuge Flocculent Chamber Worn by severe Abrasion. Replacement Linings Fail Within Two Weeks Due to Poor Adhesion The Substrate Being Coated With A Belzona Elastomer Conditioner, Belzona Release Agent Applied to the Mold Mechanical Damage
- 28. Belzona 2100 Series Elastomer Poured Between Substrate & Mould Finished Lining 6mm Thick Mechanical Damage
- 29. 1/2” Thick Rubber Rolls In a De-watering Press Wear to Exposed Metal Rolls Rebuilt Using a Belzona 2000 Series Elastomer and Formed to Exact Tolerances Using Stainless Wrapping Mechanical Damage
- 30. Gas Scrubber HCl / NaOH Containment Area Damaged and Acid Resistant Tiles Failed Chemical Attack
- 31. Floor & Wall Repaired & Coated With Belzona 4000 Magma Products Chemical Attack
- 32. A Curved Metal Patch Was Bonded to Seal & Entire Area Was Coated With Belzona Chemical Resistant Products Holed Chemical Storage Tank, Problem Area Ground for Repair Chemical Attack
- 33. Sludge Dump Truck suffered Severe Erosion Relined With Belzona Coating, Outlasted Previous Liner by 3 Years at the Same Cost Sticking Problem Also Resolved Chemical Attack
- 34. MONEY SAVING ALTERNATIVES Refurbishment Of Discarded Components Field & In House Repairs Minimum Down Time Permanent Repairs Belzona vs Component Replacement Lower Operational & Maintenance Costs Our Goal
- 35. www.belzona.com
Editor's Notes
- No matter what kind of problems you encounter in wastewater treatment industry, such as pump problem, concrete problem, leakage, mechanical damage, and chemical attack, Belzona offers polymeric solutions for the repair and maintenance for wastewater treatment industry.
- Since its beginnings in 1952, Belzona has been committed to the development and manufacture of high performance polymeric compounds as an alternative to conventional repairs, and to provide our customers with the best support through unmatched technical service. Belzona can be found all over the world with local representation in over 150 countries. Harrogate is the home of Belzona’s Research and Development Department and manufacturing plant. While Miami is the home of our Marketing Department.
- To ensure our customers the highest quality products, our manufacturing facility has attained ISO 9002 certification. This is only possible because we have complete manufacturing control over our products, thus assuring our customers a reliable source of products batch after batch. With a half century of experience we have develop techniques unique to our solutions that have proven successful for decades. Based on this success, we have compiled the Belzona Know-how System. This system has detailed information on how to perform common applications step by step. Our position in the market as the leader in polymeric solutions has gained us world wide recognition from prestigious companies where they specify Belzona procedures and products for the repair and maintenance of their equipment. Belzona Factory-trained consultants and contractors are ready to help you with your maintenance problems 24 hours a day, 7 days a week.
- Belzona manufactures a range of repair materials covering all areas within the maintenance field. Whether it be for repairing or protecting metal components, rubber components, insulation and roofing systems, concrete repairs or steel protection.
- Jim Norberg Wastewater treatment plant in North Florida February 1993 Pump impeller from a submersible pump at a sewage lift station. Severe erosion/corrosion Belzona 1111 and 1321 Steel the pump impeller had been thrown away by the owner. After rebuild, it was put back in service in a lift station. Replacement of impeller would have cost $1,600. Belzona Materials cost $250. The pump impeller fresh from the scrap pile. Rebuilding in process. Note the Belzona applicator being used to help create the contour on the Back side of the impeller. The restored impeller.
- SUCTION BELL Suction bell for a wastewater treatment plant severely eroded. Replacement coat was $8,000 with a 6-week lead time. It was rebuilt with R metal for $1,200. The tolerances were more accurate than the new suction bell that had recently been purchased & rebuilt in 1999. In Virginia By frank Barnett
- Rebuild of severely eroded pump components - wastewater treatment plant. By Mr. Mike Gudmanz
- Rebuild of severely eroded pump components - wastewater treatment plant. By Mr. Mike Gudmanz
- By Mr. Phil Putnam Hampton Roads Sanitary District – York River Plant Larry Sparrow 515 Back Creek Rd., Seaford, VA 23696 (804) 898-8372 June 1995 Badly corroded sludge pump ( impeller was frozen by rust – it would not turn.) In the past these sludge pump were scrapped and replaced cost about $6500. Ceramic S-metal $985.00 Time taken for the repair, one and a half hour Customer comments: we’ve got another one just like this. Main Customer Benefit by using Belzona: A feather in the cap of the operators here. They showed the director that they were capable of doing this job well and saving a lot of budget money both now and in the future.
- Wastewater Treatment Plant in Northwest Florida September, 1998 Wemco-muniflo rotary lobe, pump Model RPD5 Rotary pump lobes damaged by entrainment solids. 2131, 2911, 4411, 9411 Steel Replacement cost is $ 1,000 - $ 1,300 per lobe. Cost of fabricating lobe with Belzona technique is approximately $ 600 per lobe, saving the customer in excess of $ 600. Damaged lobes from pump. A perfect mold is made from new lobe using Belzona forming technique. New lobe casted with 2131. Inspection six months after installation shows no wear. One year after installation the lobes are operating perfectly.
- Wastewater Treatment Plant in Northwest Florida September, 1998 Wemco-muniflo rotary lobe, pump Model RPD5 Rotary pump lobes damaged by entrainment solids. 2131, 2911, 4411, 9411 Steel Replacement cost is $ 1,000 - $ 1,300 per lobe. Cost of fabricating lobe with Belzona technique is approximately $ 600 per lobe, saving the customer in excess of $ 600. Damaged lobes from pump. A perfect mold is made from new lobe using Belzona forming technique. New lobe casted with 2131. Inspection six months after installation shows no wear. One year after installation the lobes are operating perfectly.
- Plantation Wastewater Treatment Plant, South Florida, by Mr. Mike Hinson
- Plantation Wastewater Treatment Plant, South Florida, by Mr. Mike Hinson
- County Wastewater treatment plant in Northern Florida February, 1995 Concrete platform at wastewater treatment plant Aeration tank Spalled concrete at railings Belzona 4111 Patching with Concrete would not work. To replace the slab would have cost thousands of dollars. The Belzona 4111 solution is a quick, easy to install, permanent repair. Spalled concrete at railing, surface preparation complete. Application in progress, plywood covered with plastic sheeting being used as a former. Completed application, concrete reformed with Belzona 4111. By Mr. Jim Norberg
- Concrete crack has caused the aerator (Underground Oxygenation Reactor) loosing pressure, and leaking oxygen. The confined tank was repaired right in place. In order to pour Belzona 4111 into the form, much more portion of Belzona 4151 was used to mix with Belzona 4111. The slurry Belzona 4111 was applied in a cold day. by Mr. Sel Demarco
- By Mr. Doug Anderson, Missouri, USA.
- Pistol grit pump & separator. Blast & coat with S metal. Centrifuge influent , to get hard grit out. cut & weld clean out pipe on base of pistol grit pump, coat with S Metal. And two S Metal coating pictures. Centrifugal separator – made of stainless steel, top was cut off, blasted center pipe welded on coated with R-metal, rewelded, R metal applied to welded area to prevent bi-metallic corrosion.. The chamber is about 18”X18”. The whole thing will be $6,000 if replaced by a new unit. The the inlet pipe and Chamber worn off. The whole can, pipe and the outlet pipe lid interior was coated with Belzona R&S metal. East Tennessee, John Zick
- US government wastewater treatment plant in Northern Florida. Trickling filter bed, pedestal badly worn and corroded. A new pedestal was ordered and delivery was 8 months away. The application is working great and there is no need to replace the unit. By Mr. Jim Norberg
- 1. Primary micro-screen room. 2. Primary micro screen drum with sleeve ready to receive Belzona. 3. Sleeve being drilled for weep holes and injection fitting. 4. Sleeve in place being adjusted (aligned with set screws). 5. Sleeve in place with 1321 being injected. 7. Job almost finished, note that sleeve is sealed at drum and shaft to contain material. 8. Repair perfect ready to operate in 16 hours. By Consultant: Mr. Ron Hancock
- 7 Digester Propellers (actually a tug boat propeller reverse spinning) can only survive one year and costs $ 3500 to replace. Belzona repair with R & S metal on the propeller surface can also last a year but only cost $ 300. And the whole coating application and balancing only took 4 days. The Similar repetitive repair has been done for 4 consecutive years. In a WWTP in East Tennessee by Mr. John Zick.
- 7 Digester Propellers (actually a tug boat propeller reverse spinning) can only survive one year and costs $ 3500 to replace. Belzona repair with R & S metal on the propeller surface can also last a year but only cost $ 300. And the whole coating application and balancing only took 4 days. The Similar repetitive repair has been done for 4 consecutive years. In a WWTP in East Tennessee by Mr. John Zick.
- By Mr. Jim Anthony Parsons Engineering Service Belzona 1111 Problem:cost and down time experienced in sending shaft to be machined. After experiencing many cost effective and satisfactory Belzona (see attached 10 major projects in two years) repairs, this company which manages and operates the Jefferson Parish East Bank waste water treatment plant(a state of the art facility) decided to buy their own lathe and have been for the last two machining of shafts constantly looking for new and better ways to cut their cost of operations and enhance the quality of this operation.
- CUSTOMER Centrifuge Manufacturer, Massachusetts USA APPLICATION DATE February 2000 APPLICATION SITUATION Rubber lining on wastewater centrifuge flocculent chamber wore out due to abrasion. PROBLEM New rubber lining failed within two weeks due to poor adhesion to substrate. SUBSTRATE Steel APPLICATION METHOD Application was carried out in accordance with a modified Belzona Know-How Leaflet PDP-8. BELZONA FACTS New lining was cast with Belzona 2131. Has been running without problem. By Mr. Jeffery Hutt
- CUSTOMER Centrifuge Manufacturer, Massachusetts USA APPLICATION DATE February 2000 APPLICATION SITUATION Rubber lining on wastewater centrifuge flocculent chamber wore out due to abrasion. PROBLEM New rubber lining failed within two weeks due to poor adhesion to substrate. SUBSTRATE Steel APPLICATION METHOD Application was carried out in accordance with a modified Belzona Know-How Leaflet PDP-8. BELZONA FACTS New lining was cast with Belzona 2131. Has been running without problem. By Mr. Jeffery Hutt
- When disposing of hazardous wastes, volume is the chief cost. Landfill space is expensive, so it is cost effective to reduce the volume or bulk of the waste disposed. With sludge, the easiest way to cut disposal costs is to not pay to dispose of water. This is where the dewatering process comes into play. The belt press is a common means of drying biosolids. Water is removed by pressing the moving sludge against a porous surface (often with vacuum on the back side to aid in drawing out moisture. The water is drained off, usually back to the treatment process, and the dried cake is removed for further treatment/drying or disposal. After sufficient drying, usually down to about 50 percent moisture content, the sludge may be barged to offshore dumping sites or landfills. In some limited cases this material may be used for soil conditioning fertilization. Additional heat-assisted drying may be required to make the cake suitable for the purposes. The waste sludge is very abrasive, and over a period of time, the elastomeric press wears away unevenly. Brian Burgess has used stainless steel wrapping, and poured in Belzona 2131 (D&A Fluid Elastomer) to form a new 1/2” thick roll. These rolls typically cost in excess of $6,000.
- By Dr. Mathias Winkler, Germany.
- By Dr. Mathias Winkler, Germany.
- By Mr. Dave Lucas Chemical Storage Tank in a Sewage Treatment Plant Interior coating had failed, creating large hole near bottom of tank Belzona Super XL-Metal & Magma CR1 Steel & Epoxy Coating A grinder was used to clean & roughen the area around the 4” diameter hole. A 2’ X 2’ X ¼ “steel plate was cut & then bent to conform to the contour of the 22’ diameter tank. Super XL-Metal was applied to the cleaned & roughened surface of the tank & also to one side of the curved plate. This pate was then pressed over the hole. More XL-Metal was used around the perimeter. Once cured, the entire area was coated with Magma CR1 for excellent chemical resistance. Super XL-Metal has excellent adhesion and chemical resistance. Magma CR1 offers excellent chemical resistance for harsher chemicals. The outside of the tank was repaired using the same materials and same techniques, except that a metal plate was not required.
- Belzona keeps things moving and fight H2S chemical attack Municipal Wastewater facility in Northern Florida Dump truck bed used to haul de-watered sludge from belt press of wastewater treatment plant to land fill. H2S chemical attack and corrosion of the truck body. The customer considered once again, using a polyethylene bed liner. The problem with the bed-liner is, as the truck vibrates, moisture gets under the liner and rusts the truck bed. For basically the same cost as a bed-liner, the Belzona system was used. It is anticipated that the Belzona system will outlast the bed-liner by three years, thus offering a substantial saving to the regional wastewater facility. Sticking problem was also resolved at the same time. Belzona 6111 and 5811. By Mr. Jim Norberg
- OUR GOAL Is to provide you, our customers, cost effective solutions. We accomplish this by developing solutions that will allow you to reclaim discarded equipment. Safe and easy products that allow many of the applications to be carried out in the field thus minimizing costly down time. By focusing our solutions to address the cause of the problem, we can offer for the most part, permanent solutions that in many cases perform better than new replacement components. It is this philosophy that has made us the Industry Leaders and will provide you with significant savings in the maintenance and operation of your equipment.
- So let us know How can we help you today?