BELZONA SOLUTIONS REPAIR AND UPGRADE STEEL STRINGER SECTIONS ON HISTORIC AUSTRALIAN RAIL BRIDGE
After meeting with the client, Australian Belzona Distributor Rezitech Services PTY Ltd recommended two Belzona products to repair and upgrade the steel stringer sections of a rail bridge that were suffering from severe corrosion. A majority of rail bridges in Australia require regular cyclical maintenance to their bridge decks due to the issues caused by the deterioration of the original construction materials.
These issues have a detrimental impact on the structural integrity of the bridge deck. Therefore, Rezitech agreed that Belzona 1121 (Super XL-Metal) and Belzona 1212 would be the ideal products to repair the top flange as once cured, they provide corrosion resistance by preventing moisture ingress. In addition, Belzona 1121 (Super XL-Metal) was chosen for the larger applications due to its extended working life as it would not harden before the installation of the steel repair plates.
Steel Stringers are one of the essential components of a railway system. They are designed as load-carrying elements of a rail bridge that span under the roadway and transfer the railway loads to the trusses and beams.
After several successful trials off-site, the new deck was approved. Not only would the new deck strengthen the existing bridge deck and provide long-term durability, but it would also be more cost-effective due to the reduced need for maintenance.
Belzona 1212 is a paste-grade multipurpose, epoxy-based material that exhibits rapid cure and excellent adhesion. With its built-in surface tolerant technology, Belzona 1212 bonds tenaciously to steel substrates even when the surface preparation is minimal.
Due to time constraints, Belzona 1212 was used on the small steel stringer sections. For the larger sections, Belzona 1121 (Super XL-Metal) was first applied to the heavily corroded areas with an applicator. Once all the heavily corroded areas were filled, a further application of Belzona 1121 (Super XL-Metal) was applied and smoothed out using a trowel to leave a thin layer on the top flange.
Belzona 1121 (Super XL-Metal) is a cold-curing 100% solids epoxy composite reinforced with silicon steel alloy. The system will not corrode and resists a wide range of chemicals and is ideal for applications in hot climates or larger areas, where extended working life is required.
The steel repair plate was lifted onto the stringer and securely clamped in place; the plate was then drilled, followed by the installation of huck bolts. As the huck bolts were secured in place, excess Belzona product exuded out, ensuring there was minimal air entrapment between the plates. After the curing process was complete, the repaired stringers were successfully re-installed on the bridge deck.
A representative for the client said:
“Belzona has proven to be an excellent product for our project; It is easy to use, provides the required workability and more importantly protects and adds to the overall durability of the upgraded bridge deck.”
Rezitech has been the sole Australian Distributor for the exclusive range of Belzona repair and maintenance products since 1972. The company provides turnkey maintenance and efficiency solutions and support from on-site technical consultants who can diagnose problems and offer the appropriate solution. Rezitech also provides training for applicators and supervisory services for all Belzona applications.