Real problems, cold-applied solutions.
How Belzona systems solve the failures Louisiana plants actually deal with — corrosion, erosion, leaks, and wear — without hot work or replacement.
More case studies
Centrifugal Pump Rebuild & Efficiency Restoration
Cold-rebuilding an eroded pump casing and lining it to restore clearances, no new casting required.
Live Pipe Leak Seal & Composite Wrap
Live leak sealed and a degraded process line reinforced with an engineered composite wrap, no welding and often no shutdown.
Wastewater Clarifier & Concrete Structure Relining
Spalled, rebar-exposed concrete clarifier rebuilt and relined for continued immersion service.
Heat Exchanger Water Box Protection
Blasting, metal rebuild, and a barrier coating restore a corroded exchanger water box and tube sheet in cooling-water service.
Chute & Hopper Erosion Lining
Worn chutes, hoppers, and slurry pumps rebuilt and lined with impact- or abrasion-resistant systems matched to the wear.
Crude Storage Tank Roof Corrosion Coating
Corroded crude tank roof and shell blasted, rebuilt cold, and barrier-coated to stop further atmospheric loss.
Separator Vessel Internal Lining
Production separator rebuilt internally and lined against sour, sandy service, with no plate replacement.
Wellhead Flange Face Reforming
Corroded, pitted wellhead flange face reformed cold to a flat sealing profile, restoring the gasket seal without pulling the spool.
Furnace Stack High-Temperature Coating
A corroding furnace stack prepared and coated in situ at operating heat, with no shutdown and no cool-down.
Reactor Vessel Chemical-Resistant Relining
Failed reactor lining stripped back, attacked steel rebuilt cold, and a chemical-resistant immersion lining applied to return the vessel to process service.
Acid Pump Casing Erosion Rebuild
Eroded acid pump casing rebuilt cold and lined with a chemical- and erosion-resistant system to restore clearances.
Chemical Bund Secondary Containment Lining
Cracked concrete bund wall around a chemical tank rebuilt and lined chemical-resistant so it can hold a spill again.
Condenser Tube Sheet Galvanic Protection
Eroded tube ends rebuilt and the tube sheet face coated to separate the dissimilar metals from the cooling water and stop galvanic attack.
Turbine Pedestal Chocking and Grouting
Load-bearing chocks cast in place under a turbine baseplate that had lost foundation contact, restoring full support and alignment.
Cooling Tower Basin Concrete Relining
Spalled, cracked, rebar-exposed cooling tower basin rebuilt and lined watertight to stop leaks.
Induced Draft Fan Blade Erosion Protection
Eroded ID fan blades and housing rebuilt cold and coated to resist ash-laden gas and extend the run between rebuilds.
Potable Water Reservoir Tank Lining
Corroded potable water tank rebuilt and relined with an immersion-grade system suited to drinking-water contact.
Digester Dome Corrosion Relining
Digester dome eaten from the gas side by hydrogen sulfide rebuilt and relined against the headspace environment, no plate replacement.
Lift Station Wet Well Rebuild
Acid-gas and immersion damage in a sewage wet well rebuilt with repair mortar and lined against the corrosive flow.
Ballast Tank Pitting Rebuild
Deeply pitted seawater ballast tank cold-filled and lined for immersion service without cutting plate.
Dock Fender Rubber Rebuild
Torn and gouged dock fender rebuilt cold with a flexible elastomer back to a working profile, no fender replacement.
Splash Zone Piling Composite Repair
Wasted splash-zone piling rebuilt and reinforced with an engineered composite wrap, no welding and no pile replacement.
Black Liquor Tank Lining
Corroded and eroded black liquor tank rebuilt and lined against hot, aggressive process fluid without replacing plate.
Stock Pump Impeller Efficiency Restoration
Eroded stock pump impeller and casing rebuilt and coated back to a smooth hydraulic surface to recover lost flow.
Paper Mill Roof Leak Membrane
Failed roof seams and details sealed and overcoated with a cold liquid membrane, no tear-off.
Evaporator Vessel Hygienic Lining
Corroded evaporator vessel rebuilt and finished with a smooth, cleanable lining for hygienic product contact.
Sugar Mill Floor Chemical-Resistant Resurfacing
Broken-down sugar mill process floor repaired and resurfaced with a chemical-resistant, anti-slip system built for washdown.
Syrup Tank Base Corrosion Seal
Corroding syrup tank chime rebuilt and the base-to-foundation joint sealed to keep moisture from working back under the floor.
Gearbox Housing Bearing Bore Rebuild
Spun, worn-oversize gearbox bearing bore rebuilt cold and reformed back to dimension without machining a new housing.
Plant Floor Anti-Slip Safety Resurfacing
Worn, slick plant walkway repaired and resurfaced with an anti-slip safety floor for dependable footing.
Compressor Casing Crack and Leak Repair
Cracked, weeping compressor casing sealed and the cracked section rebuilt cold, with no hot work to risk the casting.
Apron Feeder Wear Plate Shimming
Uneven wear plates shimmed with cast conforming backing to stop the pounding, then lined for abrasion where the material rides.
Crusher Pump Volute Abrasion Lining
Worn slurry pump volute rebuilt and lined along the wear path with an abrasion-resistant composite matched to the feed, no new casting required.
Ladle Walkway Handrail Rebonding
Loose, corroded handrail stanchions rebonded and anchored to a steel-mill walkway, with anti-slip footing added and no hot work.
Mill Stand Roll Housing Bore Reclamation
Worn roll housing bores and liner seats rebuilt cold and shimmed with conforming support to restore the bearing fit, no machining required.
Valve Bonnet and Seat Reclamation
Rebuilding a passing gate valve's worn seat and bonnet faces cold to restore shutoff and a tight bonnet seal, with no new casting.
Shell-and-Tube Channel Cover and Tubesheet Repair
Eroded pass-partition rib and gasket land rebuilt, the sealing faces reformed flat, and the process side barrier-coated so the cover pulls up tight.
Agitator and Mixer Shaft Rebuilding
Worn agitator shaft seal area and journals rebuilt cold and the wetted length coated, without scrapping the shaft for a new forging.
Conveyor Pulley and Idler Lagging
Worn pulley lagging and grooved idlers rebuilt and relagged so the belt drives without slip, no replacement pulleys.
Sluice Gate and Penstock Refurbishment
Corroded sluice gate and penstock seats rebuilt and reformed flat so the gate seats square and the leak path closes.
Kiln Trunnion and Tire Seal Repair
Worn kiln trunnion roller and bearing seats rebuilt cold and dressed back to the running line, with the hot seal area coated for protection.
Cooling Tower Basin Lining
Spalled, cracking cooling tower basin rebuilt and lined as one watertight barrier without tearing out the slab.
Demister and Mist Eliminator Housing Lining
Pitted mist eliminator housing wall and pad support ledge rebuilt and lined so the demister seats true and the wall stops losing metal.
Knife-Gate Valve Seat Reclamation
Worn slurry knife-gate valve seat and gate guides rebuilt and lined so the blade shuts off square again, no replacement valve.
ID Fan Blade and Housing Erosion Lining
Eroded ID fan blades and scroll rebuilt cold and erosion-lined to bring the rotor back toward balance and restore airflow.
Wet Scrubber and Ductwork Lining
Corroding wet scrubber and ductwork blasted, rebuilt, and lined under one chemical-resistant film so the condensate runs over the lining instead of into the steel.
Boiler-Feed and Slurry Pump Rebuild
A multistage boiler-feed pump and a slurry pump rebuilt cold to original clearances and lined, so both go back to service without new castings.
Transformer Radiator Leak Sealing
Weeping transformer radiator headers and seams sealed and rebuilt with an oil-tolerant composite, then coated to keep the corrosion from spreading.
Sugar Mill Roll and Screen Rebuild
Worn mill roll journal rebuilt cold and the corroded screen plate built back up, then both protected for the grinding season.
Butterfly Valve Disc and Seat Restoration
Pitted disc edge and corroded seat rebuilt and recoated so a large butterfly valve shuts off tight again, no replacement valve.
Digester and Clarifier Mechanism Repair
Corroded digester and clarifier rake arms and drive components rebuilt and coated so the mechanism turns true again, without pulling the basin for new arms.
Loading-Rack and Bund Concrete Rebuild
Spalled loading-rack deck and bund rebuilt and lined chemical-resistant so containment holds a spill instead of soaking into the slab.
Dock Fender and Bollard Repair
Torn fender faces, corroded mounting steel, and spalled bollard-pocket concrete rebuilt in place without replacing the fender line.
FD Fan Blade Protection and Balance
Worn forced-draft fan blades rebuilt cold and coated to restore balance and the airflow the furnace needs.
Compressor Cylinder and Casing Restoration
Corroded compressor cylinder and casing rebuilt cold and the gasket land reformed flat so the joint seals, without a new casing.
Blower Housing and Impeller Erosion Lining
Eroded blower impeller and housing rebuilt and lined to restore airflow and stand up to a dust-laden stream.
Flue Gas Stack and Breeching Lining
We rebuilt and lined a flue gas stack and breeching that had thinned where acidic condensate attacked the steel below the dew point.
Ball Mill and Crusher Liner Rebuild
Worn mill liner backing and crusher transfer points rebuilt so the plates sit on a solid seat and the shell is protected from impact.
Potable Water Standpipe and Riser Lining
Corroding standpipe and riser rebuilt and lined for potable water service without cutting and replacing plate.
Process Floor Anti-Slip and Chemical Resurfacing
A worn, spalled process floor chipped out, rebuilt, and resurfaced with a chemical-resistant anti-slip system that drains and sheds washdown.
Crane Rail and Runway Support Grouting
Re-bedding a crane runway rail on a fresh full-contact grout bed so it stops rocking and pounding the support steel.
Containment Roof and Membrane Weatherproofing
A leaking plant roof over critical equipment sealed with a continuous liquid membrane, no tear-off.
Clarifier Launder and Weir Resurfacing
Spalled concrete launder and weir lip rebuilt, reprofiled to a true edge, and lined for an even overflow.
Engine and Gearbox Casing Leak Repair
Oil-weeping engine and gearbox casing sealed and rebuilt with a machinable composite, no machining or housing replacement.
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