Belzona Know-How
FOR REBUILDING DAMAGED WATER BOXES, END COVERS
AND CHANNELS
Common Problems
Leakage between passes due to
erosion/corrosion of division bars
resulting in reduced efficiency.
Set-up
All work should be carried out in strict
accordance with the relevant Belzona®
Instructions For Use.
Product selection should be made
based upon the extent of damage and
the operating conditions of the
equipment.
Where severe deterioration of the
division bar faces has occurred, it may
be necessary to reinforce the repair
area using suitable screwed bar/studs
(fig 1).
Screwed Bar
Framework
Division
Bar
Fig. 1
Suitable formers should be utilized to
reconstruct the seal face and should be
manufactured from either metal bar or
hardwood and treated with two coats of
Belzona® 9411 prior to use.
Preparation
Prepare the surfaces to be rebuilt by grit
blasting to Swedish Standard Sa2½
(near white metal finish) with a
minimum profile of 3 mils (75 microns)
using an angular grit.
Where equipment is operating in
aggressive corrosive solution, e.g.
salt water, please refer to Section 1
of the Belzona® Instructions For
Use.
www.belzona.com
HEX-2
Application
a) Forming Division Bar Faces
Secure a former along one side of the
eroded division bar and apply the
Belzona® product to a thickness slightly
greater than that required. The second
former should then be offered up to the
Belzona® product and both formers
clamped in position (fig. 2).
Belzona®
Product
Formers
Fig. 3
For further information with regard to
complete internal protection, refer to
Belzona® Know-How System Leaflet
HEX-3 "Applying Erosion/Corrosion
Resistant Coatings".
Belzona®
Product
Fig. 2
Excess material should now be
removed leaving a slight excess peak to
the center of the division bar after which
the final top former should be pressed
into the surface to form the top seal
face.
Allow the Belzona® material to cure
before removing the formers and
dressing the repair.
b) Rebuilding General Erosion
Damage
Apply a thin even film of Belzona® over
the area to be re-profiled using a stiff
short bristled brush to ensure maximum
penetration and minimal air entrapment.
Apply further layers of product using a
brush or applicator until all pitted/eroded
areas are completely filled to original
profile (fig 3).
BELZONA KNOW-HOW FOR REBUILDING DAMAGED WATER BOXES,
END COVERS AND CHANNELS HEX-2
Belzona® Technical Comparison:
Product Consistency Erosion Resistance Working Life at Full Chemical Cure at
60°F (15°C) 60°F (15°C)
Belzona® 1111 Paste Very Good 25 minutes 3 days
Belzona® 1121 Paste Good 60 minutes 7 days
Belzona® 1311 Paste Excellent 25 minutes 3 days
Belzona® 1221 Paste Good 4 minutes 30 hours
Belzona® 1511 Paste Good 40 minutes* -------**
Belzona® 4301 Paste Fair 35 minutes 14 days
* Minimum application and cure temperature is 65°F (18°C)
**Designed to cure in service. See IFU for specific details.

Belzona® System Selector:

Main System Requirement Belzona® Belzona® Belzona® Belzona® Belzona® Belzona®
1111 1121 1311 1221 1511 4301
General repairs •
Repairs where longer working life is required •
High erosion resistance •
Emergency repairs •
Repairs requiring maximum chemical resistance •
Machinable repairs • • •
Maximum heat resistance •

Recommended Equipment:
Mixing and application tools are included in  Grit Blasting Equipment  Drills / Taps
each pack of Belzona®. Prior to carrying  Clean Rags  Formers
out the repair, however, it is important that  Belzona® 9111  Stiff Bristled Brushes
all other necessary tools and equipment are  Belzona® 9411  Suitable Protective Clothing/
available on site. Every situation will be  Studs Equipment
somewhat different, but the basic  Screwed Bar
requirements could include those shown to  Grinding Equipment
the right.

For more complete technical information, please refer to the appropriate Belzona Product Specification Sheet.
For detailed instructions on surface preparation, mixing and curing, please refer to the appropriate Belzona Instructions For Use.
Comprehensive Health and Safety information is provided with the product. For more information, please contact your local Belzona representative.

The technical data contained herein is based on the results of long term tests carried out in our laboratories and to the best of our knowledge is
true and accurate on the date of publication. It is however subject to change without prior notice and the user should contact Belzona to verify ISO 9001:2008
Q 09335
the technical data is correct before specifying or ordering. No guarantee of accuracy is given or implied. We assume no responsibility for rates of ISO 14001:2004
coverage, performance or injury resulting from use. Liability, if any, is limited to the replacement of products. No other warranty or guarantee of EMS 509612
any kind is made by Belzona, express or implied, whether statutory, by operation of law or otherwise, including merchantability or fitness for a
particular purpose. Belzona products are manufactured
under an ISO 9000 Registered
Quality Management System
Nothing in the foregoing statement shall exclude or limit any liability of Belzona to the extent such liability cannot by law be excluded or limited.

Copyright © 2011 Belzona International Limited. Belzona® is a registered trademark

Printed in England Publication No. 51-5-11