Belzona Applications for Advanced Manufacturing: Top 6 Application Areas 

Physical Degradation – Threats to Smart Factories

The rapid advancement of artificial intelligence (AI) in recent years has accelerated the adoption of AI-powered systems in advanced manufacturing factories. 

However, physical degradation, such as corrosion, erosion, chemical exposure, and mechanical damage, remains a cause of unplanned downtime and production disruption. High-performance protective coatings and composite repair solutions can bridge this gap by safeguarding critical equipment, enabling timely and in-situ repairs, and ensuring that smart factories can operate at their highest efficiency.  

Belzona Applications in Advanced Manufacturing Environments

In this blog, Belzona identifies six key maintenance areas within advanced manufacturing environments where composite repair and protective coating systems provide measurable operational benefits:  

1. HVAC Systems 

HVAC stands for Heating, Ventilation, and Air Conditioning. The system is critical for maintaining temperature, air quality, and humidity in buildings, enabling personnel and machines in advanced manufacturing to operate in suitable environments. Components used in HVAC systems within industrial infrastructure commonly suffer from:   

• galvanic and electrolytic corrosion
• chemical attack
• thermal stress
• erosion and wear
• fluid leakage

Belzona offers solutions for HVAC systems. The solutions support both corrective and proactive maintenance by using rebuilding materials to restore eroded and corroded HVAC components, as well as using high-performance protective coatings for thermal insulation and areas exposed to corrosive media, whether from heat, fluids, or other process environments. The systems can resolve issues for both internal and external structures.   

• Weatherproofing Coating
  • Belzona 3211 (Lagseal): A water-based fire-resistant membrane system for waterproofing and weatherproofing all types of insulation and cladding materials.  
  • Belzona 3111 (Flexible Membrane): a solvent-free microporous coating that prevents water ingress whilst allowing trapped moisture to escape. The coating shields buildings and structures from UV radiation, thus reducing energy consumption. The system can be applied to roof protrusions, joints between roof sections, and ventilation or cooling systems. 

• Protection against corrosion from ater condensation, heat, and cleaning chemicals with the following systems: 
  • Belzona 1100 Series: For rebuilding and resurfacing worn or damaged metal surfaces, including pipes, pump casings, and heat exchanger tube sheets. 
  • Belzona 1200 Series: Fast-curing emergency paste-grade for rebuilding and resurfacing metallic parts. 
  • Belzona 1300 Series: For erosion/corrosion resistant protection of equipment subject to high-velocity flow, such as fan blades, impellers, and ducts.  
  • Belzona 5811 (Immersion Grade): For protecting surfaces in immersed conditions such as cooling tower basins and fan blades against corrosion. 

2. Machinery Foundation

In smart factories and advanced manufacturing infrastructures, precision, agility, and long-term stability are critical for equipment such as robotic arms, CNC machines, and AI-driven autonomous production systems. A minor misalignment at the machinery base can disrupt accuracy, affecting production performance and accuracy. 

• Belzona 4000 Series: A range of epoxy-based concrete repair materials. These materials are suitable for securing loose anchor bolts and filling concrete voids at the equipment foundation. 
• Belzona 7111: A high-performance epoxy chocking and grouting compound. It is a self-leveling material that provides a void-free, load-bearing interface between machinery and its foundation. Belzona 7111 supports the accuracy, reliability, and longevity of machinery foundations in advanced manufacturing and smart factory environments.

3. Power Distribution

Power supply is crucial for manufacturing processes. In smart factories or advanced manufacturing, power supply is needed not only for mechanical production but for the entire digital ecosystem, including sensors, control systems, computing devices, and cloud-connected AI platforms. Common problems with power generation equipment in industrial settings include: 

• Transformer oil leaks
• Deteriorating gaskets
• Transformer insulation decay
• Moisture ingress
• Thermal stress
• Gas and fluid leakage

Belzona composite repair materials enable rapid and in-situ repairs of transformers, cables, and auxiliary equipment without the need for hot work or extended shutdowns. These solutions help restore integrity, prevent further deterioration, and ensure uninterrupted power delivery across the smart manufacturing operations. 

• Belzona surface-tolerant solution
  • Belzona 1212: A fast-curing and surface-tolerant material, suitable for water and oil-contaminated substrates such as transformer oil leaks.
  • Belzona 5831 (ST-Barrier): A moisture-tolerant barrier coating for protecting both metallic and non-metallic surfaces. The system is formulated to ensure maximum adhesion to damp, wet, or oily surfaces, as well as underwater.

4. Metal Repair

Metal structures are fundamental components in industrial facilities due to their strength, durability, and ability to handle high loads, vibrations, and demanding operations. However, repetitive motions can fatigue metal components. This can cause operational disruptions and workplace hazards if not addressed promptly.  

Belzona offers repair solutions for metal structures as an alternative to welding. The solutions include: 

• Belzona solutions for worn shaft repair include a range of epoxy-based paste-grade materials, suitable for emergency and in-situ applications. These materials are resistant to vibration, erosion, and abrasion, helping to prevent scoring and distortion while maintaining proper shaft alignment. The material can be applied by various techniques, including: 
  • Shaft repair with a forming technique 
  • Shaft repair using the injection technique 
  • Shaft repair method for an oversized keyway 
• Belzona solutions for mechanical arm cracks or metal loss by using Belzona rebuilding materials to repair damage and Belzona protective coatings to reinforce strength of the repair
  • Belzona 1111 (Super Metal): A workhorse of the Belzona 1000 Series, designed for structural bonding and creating irregular load-bearing shims. 
  • Belzona 1212: A fast-curing, paste-grade system suitable for emergency repairs and situations where access for surface preparation is limited. 
  • Belzona 7311: A solvent-free fatigue-resistant adhesive for structural bonding applications requiring high mechanical strength, cleavage resistance, and shear resistance 

5. Floor Proofing

• Floor protection and non-slip coating 
  • Belzona 4411 (Granogrip): a three-component system (base, solidifier, and aluminum oxide aggregate) that has chemical-resistant properties. By adopting Belzona 4411 (Granogrip), asset owners can ensure a non-slip surface and avoid damage from chemical spillage on the floor. The system is available in yellow and grey, ensuring high visibility on the floor where required. 
  • Belzona 5231 (SG Laminate): A liquid-applied, slip-resistant floor coating specifically designed for surfaces subject to chemical exposure and abrasive conditions. This product is available in dark grey, light grey, and yellow. 

• Electrostatic dissipative coating (ESD coating) 
  • Belzona 5813: An ESD coating that provides a static dissipative barrier, reducing spark-related hazards and helping manufacturers comply with ESD control requirements within their facilities.  

6. Conveyor System

In smart factories, conveyor systems support the movement of goods, mechanical arms, and other automated vehicles. These systems enable continuous material handling and streamline operations, directly influencing production capacity and efficiency. All components associated with the conveyor systems require effective repair and protection against heavy loads and operational damage.  

Belzona can offer a range of elastomers for repairing rubber components on conveyor systems, as well as epoxy-based materials for metallic structures of the conveyor systems.

• Belzona Elastomeric Polymers: Belzona 2000 Series is a range of elastomeric solutions suitable for rubber repair on conveyor systems such as conveyor belts. By using elastomeric materials, the asset owner can reduce downtime while extending the lifespan of the conveyor systems.  

• Cold-applied solutions for the metallic structures of conveyor systems: By using Belzona epoxy-based materials, asset owners can mitigate operational disruption. The metal components of transport systems in smart factories, such as mechanical arm rails, rollers, and pulleys, can benefit from Belzona’s epoxy-based materials. These materials can be contoured to the geometries of the metal structures used in conveyor systems for manufacturing processes. 

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