- Why High-Temperature Pipework Fails in the Mining Industry
- Step-by-step Guide – How to Repair a Corroded Pipework with High Temperature Epoxy Solutions
- Step 1: Surface Preparation
- Step 2: Hole Patching – Belzona SuperWrap II
- Step 3: Overcoating with Belzona 1593 High Temperature Epoxy Coating
- Step 4: Cold Plate Bonding with Belzona 1511 (Super HT-Metal)
- The Result
- About the Belzona Distributor – Rezitech
- Frequently Asked Questions
- Learn More
Corroded pipework operating at elevated temperatures presents a significant maintenance challenge, particularly where corrosion has resulted in thin wall or through-wall defects. Factors such as aggressive process media, thermal cycling, and restricted access often make conventional repair methods such as welding or pipe replacement costly, disruptive, and difficult to execute safely.
In these situations, high temperature epoxy solutions provide a practical, engineered repair solution. When combined with composite reinforcement systems, high temperature epoxy materials can be used to restore wall thickness, rebuild damaged areas, and provide long-term corrosion protection, without hot work and with minimal downtime.
Why High-Temperature Pipework Fails in the Mining Industry
In mining and smelting operations, pipework selection is driven by pressure, temperature, abrasion, and corrosion resistance. Common materials include:
- Carbon steel
- High temperature and pressure resistance
- Strong and durable
- Cost‑effective
- Wear resistant
- Suitable for heavy machinery and structural applications
- HDPE (High Density Polyethylene)
- Corrosion‑proof
- Chemical resistant
- Flexible
- Lightweight
As a result, carbon steel remains the dominant material for critical high-temperature mining pipework.
Step-by-step Guide – How to Repair a Corroded Pipework with High Temperature Epoxy Solutions
This article provides a step-by-step guide to repairing corroded pipework using high temperature epoxy solutions, based on a real application on a steam condenser header operating in elevated temperature service.
To ensure effective pipe repair, restore wall thickness, and deliver long-term corrosion protection at high temperatures, a repair system was selected comprising Belzona’s high-strength composite wrap Belzona SuperWrap II and pre-rolled doubler plates, cold bonded to the pipe using Belzona 1511 (Super HT-Metal), a high temperature epoxy repair composite.
Step 1: Surface Preparation
Both the doubler plates and corroded pipe repair areas were grit-blasted to achieve SSPC-SP10 / NACE 2 / Sa 2 ½ (Near White Metal) with a 3 mil (75 µm) anchor profile. All surfaces were then cleaned with a cleaner/degreaser) to ensure optimal cleanliness.
Step 2: Hole Patching – Belzona SuperWrap II
Belzona SuperWrap II reinforcing sheets were pre‑cut and coated with Belzona SuperWrap II (1983 Resin). These layers were then applied to the affected areas of the header pipes and consolidated using a roller.
Step 3: Overcoating with Belzona 1593 High Temperature Epoxy Coating
After the Belzona SuperWrap II patches had reached the appropriate overcoating stage, Belzona 1593, a high temperature epoxy coating designed to deliver long term corrosion and chemical resistance to equipment operating under continuous immersion up to 160°C (320°F), was applied over the Belzona SuperWrap ll patches to provide enhanced chemical protection.
Step 4: Cold Plate Bonding with Belzona 1511 (Super HT-Metal)
In other areas, doubler plates were applied and cold bonded using Belzona 1511 (Super HT-Metal), in addition to the Belzona SuperWrap II patches. This is a high-temperature epoxy repair compound designed for metal repair and equipment rebuilding, offering excellent corrosion protection. Under immersion, Belzona 1511 (Super HT-Metal) is suitable for applications up to 150°C (302 °F).
Surfaces were thoroughly wetted out, and an additional layer of Belzona 1511 (Super HT-Metal) was applied to the surface of the pipe to fill any pitting and restore the surface back to its the original profile. The doubler plate was then pressed onto the pipe and held in place until the product cured.
The Result
The high temperature epoxy pipework repair was completed successfully, resulting in a durable, long-term solution capable of withstanding the required thermal and chemical service conditions. The repair avoided welding and pipe replacement, minimised downtime, and returned the system to service quickly and safely.
About the Belzona Distributor – Rezitech
Established in 1968, Rezitech is the sole Australian Distributor for Belzona. Rezitech offers a comprehensive range of industrial protective coatings and epoxy metal repair composites to many different industries including: oil and gas, mining, power, water and waste water, pulp and paper, marine, manufacturing, amongst others.
The application images shared in this case study were captured during the repair and demonstrate how high temp epoxy systems can be applied in real-world operating conditions by trained and experienced personnel.
Frequently Asked Questions
What epoxy can withstand high temperatures?
High‑temperature epoxy systems are specially formulated to maintain adhesion, mechanical strength, and chemical resistance under elevated‑temperature operating conditions. While standard epoxies tend to soften or lose strength when exposed to heat, high‑temperature Belzona systems are engineered for service in hot process environments, including continuous immersion in heated fluids and repeated thermal cycling.
Where are high temperature epoxy systems most commonly used?
High temperature epoxy systems are widely used in industries where equipment is exposed to heat, pressure, corrosion, or abrasion. Typical applications include:
• Oil & gas and petrochemical plants:
protection and repair of pipelines, vessels, heat affected areas, and other high temperature process equipment.
• Mining operations:
repair and protection of piping, chutes, and equipment handling abrasive or chemically aggressive slurries.
• Power generation and steel manufacturing:
refurbishment of scrubbers, ducts, worn pipework, and high temperature process components.
What repair solution is used for the high-temperature pipework?
In this case, the repair utilised a combination of a high‑strength composite wrap system (Belzona SuperWrap II) and pre‑fabricated steel doubler plates that were cold‑bonded using a high‑temperature epoxy repair composite. This solution restored structural integrity and wall thickness while providing long‑term corrosion resistance at the required operating temperature of 100 °C (212 ° F), even under slightly acidic conditions.
What is the highest temperature that Belzona epoxy materials can withstand?
Belzona offers several high‑temperature epoxy repair composites and coatings formulated for elevated‑temperature service. Examples include:
- Belzona 1593: suitable for continuous immersion up to 160 °C (320 °F) and capable of withstanding steam‑out conditions up to 250 °C (482 °F)
- Belzona 1511 Super HT-Metal): designed for high‑temperature metal repair and rebuilding, with service capability up to approximately 150 °C (302 °F).
- Belzona 1813: an abrasion‑resistant high‑temperature composite suitable for dry service conditions up to around 200 °C (392 °F).
Learn More
Contact Your Local Distributor to Learn More About High Temperature Epoxy Solutions
Rhiannon has been working for Belzona for over 16 years and has recently joined the Marketing Team in a Supervisory role. Her expertise lies in lead generation, social media strategy, content marketing and email campaigns.
