BELZONA KNOW-HOW
®
FOR THE REPAIR AND MAINTENANCE OF
GENERAL EQUIPMENT
BELZONA
GEQ
BELZONA® KNOW-HOW
FOR THE REPAIR AND MAINTENANCE OF GENERAL EQUIPMENT
Shafts and Bearings ...................... Rebuilding scored shafts
Repairing worn keyways
Repairing scored hydraulic rams
Rebuilding loose spline housings
Rebuilding loose bearing housings
Pages 4 & 5
Belzona 1000 Series Products: Highly advanced,
Pumps and Valves ................................. Page 6
Casings ................................................. Page 7
Rebuilding erosion / corrosion damage
Protecting against erosion / corrosion
Repairing stripped threads
Rebuilding holed or cracked casings and blocks
polymer-based systems specifically designed to repair and
rebuild metals damaged by wear, abrasion, impact, chemical
attack, and erosion / corrosion. The products consist of a
metallic base and solidifier which are easily mixed and
applied, resulting in a repair that can meet, and often
exceed, the durability of the damaged substrate.
Conveyor Systems....................... Page 8
Repairing torn conveyor belts
Protecting fasteners
Belzona® 1111... 3:1 by volume
Rubber Components ............................ Repairing damaged hose and electrical cable coverings
Repairing rubber tank linings
Page 9
Tanks and Piping Systems................... Page 10
Repairing leaking tanks and pipes
Repairing damaged flange faces
Repairing eroded pipe bends
Other Products or Services ................ 2
Page 11
Belzona 2000 Series Products: Superior elastomeric
polymer systems for mechanical repairs requiring flexibility
and impact resistance. Conveyor belts, linings, hoses, cables
and other rubber components can be repaired and rebuilt
using these advanced systems. The resulting repairs are
extremely durable, yet retain the elastic properties of the
original material.
BELZONA® TECHNICAL COMPARISONS
BELZONA PRODUCTS FEATURED
IN THIS BROCHURE:
Mechanical Repairs
1111
1121
1131
1221
type
paste
paste
paste
paste
compressive strength
high
high
high
medium
adhesion to steel
high
high
high
very high
working life 60°F (15°C)
25 min.
60 min.
25 min.
4 min.
full mechanical cure 60°F (15°C)
36 hrs.
72 hrs.
36 hrs.
1½ hrs.
Belzona® 1111: The fully machinable engineering grade
repair.
Belzona® 1121: Offers extended usable life when more
time is required for the application.
Belzona® 1131: Fully-machinable grade with selflubricating properties.
Belzona® 1221: The emergency grade material for all leak
repair applications.
Belzona® 1311: The rebuilding version of Belzona’s
erosion / corrosion resistant system.
1811
Belzona® 1321: Surface protection against all forms of
erosion / corrosion.
Fluid Flow Repairs
1311
1321
1341
1391
type
paste
fluid
fluid
fluid
paste
compressive strength
high
high
medium
high
medium
adhesion to steel
high
high
high
high
high
Belzona® 1391: Provides erosion / corrosion protection
and high wet heat resistance.
cavitation resistance
good
good
good
Belzona® 1811 / 1812: Abrasion resistant lining materials.
Belzona® 2111: A rebuilding material for elastomer repairs.
abrasion resistance
very good very good
very good very good
1812
good
very good
excellent
wet heat resistance
good
good
good
very good
good
working life 60°F (15°C)
25 min.
60 min.
50 min.
60 min.
90 min.
45 min.
full mechanical cure
60°F (15°C)
36 hrs.
48 hrs.
7 days
4 days
4 days
Belzona® 1341: The efficiency enhancement coating.
Belzona® 2121: An abrasion resistant flexible coating.
Belzona® 2131: A casting version of the Belzona abrasion
resistant 2000 Series products.
Belzona® 2211: A repair and rebuilding grade elastomer
for soft, flexible repairs and for expansion joints.
Elastomers
2111
2121
2131
2211
2221
2311
type
paste
fluid
fluid
paste
fluid
paste
hardness Shore A
85
85
85
70
65
75
abrasion resistance
high
high
high
medium
medium
medium
working life
60°F (15°C)
20 min.
20 min.
20 min.
15 min.
20 min.
4 min.
full mechanical cure 60°F (15°C)
48 hrs.
48 hrs.
48 hrs.
36 hrs.
36 hrs.
1½ hrs.
Belzona® 2221: A fluid grade for horizontal expansion
joints.
Belzona® 2311: An emergency grade flexible repair
material.
For a full range of Belzona Products please
consult your Belzona Consultant.
Working life will be reduced at higher temperatures and extended at colder ones.
The cure times shown will be shorter at higher temperatures (and for thicker
applications), and longer under cold conditions. The careful use of heat lamps or
warm air blowers can greatly speed the curing process.
3
SHAFTS AND
BEARINGS
Scored Shafts
Problem: Shaft bearing areas
have been scored by slipping or
failed bearings.
Belzona Solution: Rebuild the
scored area with Belzona
Systems, allowing a new bearing
to be installed. This is done
without having to replace
the shaft, and without heat,
eliminating the possibilty of
warping. Repairs are often
performed in place, without
having to disassemble the
machine or remove the shaft.
Worn keyways
Problem: The keyway has
become worn and over-sized,
causing vibration, misalignment,
and stress on couplings.
Belzona Solution: Reform the
keyway with Belzona Systems.
Using the key as a former, a
perfect zero-tolerance fit is
created. With no possibility of
movement and 100% contact
across the faces, mechanical
power is transmitted smoothly
from start up to shutdown.
4
Scored Hydraulic Rams
Problem: The ram surface has
been scored. Oil seals become
torn and hydraulic fluid is lost.
Belzona Solution: The score is
ground out, filled, and reshaped
using Belzona Systems. This is
done locally, without welding,
machining, or rechroming. In
many cases, the repair can be
completed without disassembly.
Loose Spline Housings
Problem: The socket of a spline
coupling has become loose,
allowing excess vibration, uneven
power transmission, and damage
to the male spline.
Belzona Solution: Rebuild the
socket with Belzona Systems. The
male spline can be used to reform
the intricate mating surfaces. This
will provide smooth mechanical
transmission and 100% contact
between the coupled parts.
Loose Bearing Housings
Problem: A bearing or bushing
housing has become worn,
allowing the bearing to vibrate or
become misaligned, or permitting
a pin to pound into the housing
with each movement.
Belzona Product Selector
1111
1121
1131
1221
•
•
scored shafts
•
worn keyways
•
•
scored hydraulic rams
•
•
loose spline housings
•
•
loose bearing housings
•
•
•
Belzona Solution: Rebuild the
bearing housing with Belzona
Systems. In many cases, the
bushing or bearing itself can
be used to reform the housing
in place, without disassembly,
machining, or line boring.
•
5
PUMPS AND VALVES
Erosion / Corrosion Damage
Problem: Erosion, coupled with
corrosion, entrainment, and
cavitation, have worn the interior
surfaces of fluid handling
equipment. Efficiency and output
are down, while costs are up.
Belzona Solution: Erosion damage
maybe rebuilt without welding.
Flow contours and wear ring
seats can be recreated without
machining. Most repairs can be
carried out where the machinery
sits.
Erosion / Corrosion
Protection
Problem: After damaged areas
are rebuilt, the potential exists
for erosion / corrosion to continue
attack in other areas.
Belzona Solution: Belzona
Systems are applied as coatings to
casings already built. They can also
be applied to new or undamaged
casings and impellers as part of a
preventive maintenance program.
Pump Efficiency
Problem: Pumps running below
their designed efficiency.
Belzona Solution: Belzona
efficiency enhancement coatings
can restore lost efficiency in old
pumps and can boost energy
efficiency and cost savings in new
pumps.
Belzona Product Selector
fluid leaks
erosion / abrasion protection
1111
1221
•
•
1321
6
2311
•
•
rubber substrates
porosity
1811 / 1812
•
•
•
CASINGS
Stripped Threads
Problem: Over-tightening or
corrosion has caused threads to
become loose or to strip out.
Common areas for this are drain
plugs, vents, pump casings and
engine blocks.
Belzona Solution: Rebuild, or even
create, stripped out threads with
Belzona systems, using the bolt
or the plug itself as a former. No
welding, drilling tapping or thread
inserts are required.
Holed or Cracked Casings
and Blocks
Problem: A connecting rod
thrown through the block wall,
or casing that has cracked due
to freezing without having been
properly drained. Such holes and
cracks normally relegate casings to
the scrap heap.
Belzona Solution: Where the casing is structurally sound, Belzona
Systems can be used to repair the
damage. Cracks, holes and gaps
can be bridged, and the repair will
be completely resistant to water,
coolant, oil, many chemicals, and
high temperatures.
Belzona Product Selector
erosion / corrosion damage
1111 1121 1221 1311 1321 1341 1391
•
•
•
erosion / corrosion protection
•
•
stripped threads
•
•
•
holed or cracked casings and blocks
•
•
•
•
•
•
•
7
CONVEYOR SYSTEMS
Belt Fasteners
Problem: Belt fasteners have
become damaged by abrasive
material on the belt, allowing
particles to fall between clips.
These are also areas where
bacteria can grow.
Belzona Solution: The fasteners
can be covered with a fast-acting,
cold curing Belzona System,
providing protection against
abrasion and corrosion. Protecting
the bottom of the fasteners can
prevent damage to drive rollers.
Torn Conveyor Belts
Problem: A rip or tear has ocurred
in the belting.
Belzona Solution: Belzona systems
can be used to effectively repair
the damage without removing the
belt, and without hot vulcanizing
equipment. The “cold vulcanized”
repair can be ready for use in less
than two hours under normal
conditions.
8
RUBBER
COMPONENTS
Damaged Hoses and
Cable Coverings
Problem: Constant wear or
mechanical damaged has removed
the outer rubber layer from hoses,
cables or electrical conductors.
Belzona Solution: Rather than
replacing or splicing in a new
section, Belzona Systems can be
used to repair the damaged area.
No heat or vulcanizing is required,
and the repairs can be normally
carried out on site.
Damaged Rubber Linings
Problem: Damage to the rubber
lining has allowed the liquid
to work behind the lining. This
will destroy the bond, and allow
corrosion and chemical attack to
destroy the tank wall.
Belzona Solution: The existing
lining and tank wall can be
repaired using Belzona Systems.
The original lining must be
removed back to where it is still
firmly bonded. If the lining needs
to be entirely replaced, one of the
chemical-resistant Belzona coating
systems may be the solution.
Belzona Product Selector
2111 2121 2131 2211 2221 2311
belt fasteners
•
torn conveyor belts
•
damaged hoses and cable coverings
•
damaged rubber linings
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
9
TANKS AND PIPING
SYSTEMS
Leaking Tanks and Pipes
Problem: Corroded joints,
welds and seams are common
causes of leaks in tanks and
associated pipework. Corrosion
damage, product loss, ground
contamination and costly clean up
are some of the consequences.
Belzona Solution: Leaking areas
can be sealed quickly from the
outside using Belzona systems.
Repairs can be made to a wide
variety of substrates including
metal, concrete, fibreglass and
rubber.
Damaged Flange Faces
Problem: Corrosion, steam
cutting, distortion or simple
misalignment will prevent flanges
from sealing properly.
Belzona Solution: Corrosion pitted
or wire drawn flanges are quickly
and simply repaired without the
need to weld or machine.
Eroded Pipe Bends
Problem: Bends and elbows are
particularly prone to erosion and
abrasion in pneumatic conveyers
and slurry systems.
Belzona Solution: Belzona systems
can extend the life and provide fast
back-to-service times of thinned
wall or perforated pipework.
Belzona Product Selector
1111
1121
1221
leaking tanks
•
•
•
leaking pipes
•
•
•
porosity
•
erosion / corrosion protection
•
abrasion protection
10
1321
1391 1811 / 1812
•
•
BELZONA PRODUCTS & SYSTEMS
Belzona also offers a wide range of quality products and systems for the repair
and protection of Machinery & Equipment and Buildings & Structures.
Belzona 3000 Series
Polymeric Membranes for the waterproofing
and weatherproofing of buildings, structures
and insulation
A range of liquid applied waterproofing membranes for
the repair and protection of buildings and structures, and
for encapsulation of fire retardant materials.
Belzona 4000 Series
Magma Polymers for the repair and protection
of concrete
A range of high performance polymeric concrete repair
and coating materials. These reactive systems can be
used to rebuild or resurface damaged concrete, protect
surfaces against chemical attack and abrasion, provide
waterproofing under negative pressure situations and
create safety grip systems.
Belzona 5000 Series
Environmental Polymers helping to conserve
the world’s resources
A range of high performance polymeric systems for
the protection of machinery, equipment, buildings and
structures against abrasion, chemical and environmental
attack.
High Temperature Coatings
Belzona coatings are designed for extreme operating
conditions ranging from chemical containment areas,
tanks, pumps and heat transfer equipment.
Belzona has more than
50 products available in a
variety of packaging
systems
The applications for Belzona
Systems are limited only by the
user’s imagination! Additional
information is available
on Belzona Know-How for
the repair, renovation and
reclamation of:
• Centrifugal Pumps
• Engines and Casings
• Fans, Blowers and
Compressors
• Floor Problem Areas
• Gaskets Seals and Shims
• Heat Exchangers
• Mechanical Power
Transmission
• Positive Displacement
Pumps
• Roof Problem Areas
• Ships and Offshore
Structures
• Solids Handling Machinery
• Tanks and Chemical
Containment Areas
• Valves, Pipes and Fittings
• Wall Problem Areas
EXPERIENCE
is what sets Belzona apart.
Since 1952, Belzona has
been developing advanced
polymeric products and
applying them to the
maintenance needs of
industry.
KNOWLEDGE
that comes from over five
decades of research and
development. Belzona’s
laboratories are a constant
source of new technological
breakthroughs.
PRODUCTS
that are respected and
used around the world, and
manufactured under the
strictest quality controls.
TECHNOLOGY
is the key to Belzona’s
ongoing commitment to
maintenance engineering.
PEOPLE
who are highly trained
experts in their field.
Belzona Consultants are
knowledgeable in solving
the problems of your specific
industry.
ISO 9001:2000
Q 09335
ISO 14001:2004
EMS 509612
11
The Global First Choice for Industrial Protective Coatings & Repair Composites
With Distributors operating in over 120 countries worldwide, Belzona Products and service
are never far away. Local support is provided by a network of factory-trained Technical
Consultants who diagnose the problem, recommend the Belzona Solution and provide on-site
application training and supervision when required. Alternatively for customers without their own maintenance
teams, application services can be recommended.
Yo u r L o c a l C o n t a c t I s :
Belzona Polymerics Ltd.
Claro Road, Harrogate
North Yorkshire, HG1 4DS, England
Tel: +44 (0) 1423 567641
Fax: +44 (0) 1423 505967
belzona@belzona.co.uk
Belzona Inc.
2000 NW 88th Court
Miami, Florida 33172, U.S.A.
Tel: +1 (305) 594-4994
Fax: +1 (305) 599-1140
belzona@belzona.com
Belzona Asia Pacific.
Rattakit Building,
29/13 Moo 9, Sukhumvit Road,
Nongprue, Banglamung,
Chonburi 20150, Thailand
Tel: +66 38 378099
Fax: +66 38 378098
belzona@belzona.cn
w w w. b e l z o n a . c o m
Copyright © 2007 by Belzona International Ltd. All rights reserved. No part of this work covered by the copyrights hereon may be reproduced or used in any other form or by any means - graphic, electronic, or
mechanical including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of the publisher.
®Belzona is a registered trademark.
Printed in U.S.A.
Publication No. GEQ01 (0407)