Flange Protection: How to Apply Belzona 3412 by Brush and Spray

Belzona’s flange protection systems eliminate the need for conventional cut and weld methods involving hot work and allow for a simple application in emergencies, especially in areas with limited access, such as on offshore platforms. Therefore, the Belzona Flange Face Forming Kit is a unique repair kit developed to aid flange face protection by combating the common problems with mating surfaces of flanged joints, such as heat distortion, flange corrosion, and erosion. In conjunction with Belzona 2-part epoxy repair composites, such as Belzona 1111 (Super Metal), this flange repair kit provides a complete package solution that is cost-effective and simple to implement.

Flange Protection Using Belzona 3412

Belzona 3412 is a liquid-applied membrane system that offers long-term flange protection from exterior damages. The durable system can be used for pipe flange protection of different shapes, sizes, or configurations from crevice, galvanic and atmospheric corrosion and completely encapsulate the flange to exclude any moisture.

When used in combination with the release agent/corrosion inhibitor, Belzona 8411, the coating can be easily cut, peeled back, and resealed to allow inspection and maintenance of fastenings. Once the required maintenance has been completed, the membranes will fold back to their original positions and can be sealed with a further quantity of Belzona 3412. The system can be brush- or spray-applied.

How To Apply Belzona 3412 by Brush or Spray

Note: Complete Steps 1–5 to prepare the flange before proceeding with either the brush or spray application of Belzona 3412.

How to Prepare the Flange Before Applying Belzona 3412

Step 1: Clean and Prepare the Surface

Clean the surface of the pipe and flanged connections to remove all dirt, grease, and other surface contaminants. Thoroughly abrade the surface with abrasive paper (sandpaper) or wire brush to remove all gloss and provide a good key for the Belzona coating.

Step 2: Tape off the Area

Apply masking tape over the two bond areas to protect the pipe areas from accidental overspray.

Step 3: Seal the Gap

To seal the gap between the flange faces, cut a strip of tape to the correct width and apply it over the gap.

Step 4: Apply Belzona 8411

To allow assess to bolts and flanges in the event of required maintenance, we recommend the application of Belzona 8411 by brush or spray. This also provides an optimum level of corrosion protection. Once the Belzona 8411 is touch dry, remove the masking tap and reapply it.

Step 5: Protective Bolt Caps

Fit plastic caps over the nuts/bolts.

How To Brush Apply Belzona 3412

Brush application of Belzona 3412 is a straightforward and effective method for flange protection, particularly useful for smaller or irregularly shaped flanges. This process ensures comprehensive coverage, providing robust protection against flange corrosion and other environmental threats.

Note: Complete Steps 1–5 to prepare the flange before proceeding with either the brush or spray application of Belzona 3412.

Step 6: Mix Belzona 3412

Empty the entire contents of the Belzona 3412 base and solidifier and thoroughly mix in the bowl provided for at least three minutes.

Step 7: Apply Belzona 3412

Using a brush, apply the mixed Belzona 3412 directly onto the prepared surface using long, light strokes. Ensure the material does not extend outside the prepared area.

Step 8: Add Belzona 9311 (Reinforcing Sheet)

While the first coat of Belzona 3412 is still wet, bed strips of Belzona 9311 around the circumference of both ends of the pipe and the flange.

Step 9: Second Coat of Belzona 3412

As soon as the first coat is touch dry, mix and apply the second coat of Belzona 3412. Belzona 3412 is available in grey and bright orange for high visibility.

How To Spray Apply Belzona 3412

Spray application of Belzona 3412 offers an efficient and uniform method for flange protection across larger or more complex areas. This technique provides thorough encapsulation of flanges, ensuring high-performance protection against flange corrosion and other damaging factors.

Step 6: Mix Belzona 3412 and Fill the Spray Gun Cartridge

Empty the entire contents of the Belzona 3412 base and solidifier and thoroughly mix in the bowl provided for at least three minutes and transfer into the cartridge of a suitable spray gun.

Step 7: Spray the First Coat of Belzona 3412

Spray the material over the entire area ensuring it does not extend outside the prepared area.

Step 8: Add Belzona 9311 (Reinforcing Sheet)

While the first coat of Belzona 3412 is still wet, bed strips of Belzona 9311 around the circumference of both ends of the pipe and the flange.

Step 9: Spray the second Coat of Belzona 3412

Mix and spray apply the second coat of Belzona 3412 once the first coat is touch dry.

How to Peel and Reseal Belzona 3412 for Inspection and Maintenance

When used with Belzona 8411, a release agent and corrosion inhibitor, Belzona 3412 can be cut and peeled back for inspection during maintenance, then resealed to provide continued protection.

Step 1: Cut Between the Flange Faces

When maintenance or inspection are required use a sharp knife to cut through the Belzona 3412 in the gap between the flange faces

Step 2: Peel Back the Belzona 3412

Peel back the Belzona 3412 along with the bolt caps to expose the bolts and flanges

Step 3: Reinstate and Reseal the Repair

Once maintenance is complete, fold the material back into position. Clean and degrease around the flange circumference if required, then use Belzona 3412 and Belzona 9311 (Reinforcement Sheet) to reinstate and reseal the repair.

Belzona’s flange protection systems, including the Belzona Flange Face Forming Kit and Belzona 3412, offer comprehensive solutions to combat corrosion, erosion, and damage to flanged joints. By eliminating hot work and providing an easy, cost-effective application process, these systems ensure long-term flange-face protection and simplified maintenance, making them ideal for use on offshore platforms and in various industrial settings.

Paola Chavez

Paola Chavez, born in San Pedro Sula, Honduras, holds a Bachelor of Science degree in Chemical Engineering from Florida State University in Tallahassee, Florida, United States. As a distinguished Technical Service Engineer at Belzona, Inc. based in Miami since 2021, Paola excels in providing comprehensive office and field-based application support, ensuring the optimal use of Belzona products across diverse projects.

An integral member of the Belzona Corporate Oil and Gas Team, Paola plays a pivotal role in business development, contributing her extensive knowledge to specifications, testing, approvals, and applications within the energy sector. Her expertise and unwavering dedication have solidified her reputation as a key contributor to the Team’s success and the broader industry. Indeed, Paola has provided application supervision and technical support across many different locations worldwide including North America, South America and the Asia Pacific region, amongst other places. In 2024, she delivered a seminar on Belzona’s cold bonding solutions at ADIPEC Downstream Technical Conference in Abu Dhabi.

In addition to her engineering prowess, Paola is an AMPP Certified Coatings Inspector Level 2 (Certification Number: 106760) and actively participates in the Association for Materials Protection and Performance (AMPP) through Belzona’s corporate membership. Her certifications underscore her commitment to maintaining the highest standards in materials protection and performance.