Belzona Product Centre / Case Studies
Know-How in Action
Documented repairs, from Belzona's own files.
These are genuine Belzona KHIA (Know-How in Action) case studies from Belzona’s global library. The same systems, applied in Bangladesh by S.A. International’s Belzona-trained crews.
Cement
CementSeparator shell protected from severe abrasion
A cement plant separator shell had worn so badly that structural defects threatened both safety and operation. Rebuilt and lined with ceramic composites — restoring integrity without fabricating a replacement.
Belzona 1311Belzona 1812Belzona 1391TView KHIA →PDF ↓Belzona KHIA · 2024
CementCement ball mill life extended after tile-gap abrasion
Cement particles trapped under the mill’s lining tiles were grinding away the shell itself. Abraded areas rebuilt with machinable metal-repair composite.
Belzona 1111View KHIA →PDF ↓Belzona KHIA · 2024
CementFan impeller edges rebuilt after dust erosion
Dusty material flow had eaten away the edges and blades of a fan impeller. Blades rebuilt and armoured with fine-particle ceramic carbide lining.
Belzona 1812View KHIA →PDF ↓Belzona KHIA · 2024
CementVRM crusher bearing housing reclaimed in place
Vibration wore the bearing housing until the bearing ran loose. Rebuilt to dimension with metal-repair composite and release agent — no machining.
Belzona 1121View KHIA →PDF ↓Belzona KHIA · 2024
Cement15-metre rotary slag dryer lined against wear
A 15 m × 3.6 m rotary dryer wearing through from tumbling abrasion was lined with ceramic carbide wear composite — a maintainable lining instead of recurring fabrication.
Belzona 1811View KHIA →PDF ↓Belzona KHIA · 2019
CementCement plant diverter gate life doubled
An AR 400 steel diverter gate wore out every 9 months under aggregate impact. Rebuilt and coated with ceramic wear compound — doubling service life without replacement.
Belzona 1311Belzona 9811View KHIA →Belzona KHIA · 2006Power Generation
PowerCondenser tube sheets rebuilt at a major power plant
Severe corrosion was eating condenser tube sheets and tube ends. Rebuilt with metal-repair composite and protected with a smooth ceramic barrier — avoiding re-tubing.
Belzona 1111Belzona 1321View KHIA →PDF ↓Belzona KHIA · 2026
PowerSeawater intake pump diffuser bowl restored
Marine exposure left the diffuser bowl and vanes severely corroded. Internals rebuilt with ceramic composite and finished with an erosion-corrosion barrier.
Belzona 1311Belzona 1321View KHIA →PDF ↓Belzona KHIA · 2025
PowerFly ash elbow holed in months — wrapped for good
A fly ash line elbow wore through months after replacement. Rebuilt with high-temperature abrasion paste and reinforced with SuperWrap II — ending the cycle.
Belzona 1813Belzona 1983View KHIA →PDF ↓Belzona KHIA · 2025
PowerHigh-pressure steam leak sealed at blowdown elbow
A steam leak at a blowdown elbow threatened safety and output. Repaired and reinforced with the SuperWrap II composite system for hot, pressurized service.
Belzona 1983SuperWrap IIView KHIA →PDF ↓Belzona KHIA · 2025
PowerTransformer oil leak sealed live — no oil drain-down
A transformer flange leak would have meant draining the unit. Stemmed and sealed in place with surface-tolerant composites — transformer kept in service.
Belzona 1161Belzona 5831LTView KHIA →PDF ↓Belzona KHIA · 2024
PowerGas turbine air intake roof saved from corrosion
Humidity had severely corroded a GT air intake roof. Steel rebuilt and sealed with surface-tolerant barrier coatings — no new roof sections fabricated.
Belzona 1161Belzona 5811Belzona 5831View KHIA →PDF ↓Belzona KHIA · 2025
PowerCooling tower riser pipe reinforced in the splash zone
Splash-zone exposure caused metal loss on a riser pipe. Metal restored with wet-tolerant composite and protected with high-build immersion coating.
Belzona 1161Belzona 5841View KHIA →PDF ↓Belzona KHIA · 2026
PowerCooling water pump shaft rebuilt in situ
The main cooling water pump drive shaft was damaged by bearing failure. Previous hot-metal spray caused pick-up. Rebuilt in hours with bearing metal composite — pump returned to service immediately.
Belzona 1131View KHIA →PDF ↓Belzona KHIA · 2007
PowerFGD scrubber piping saved from lime slurry erosion
Lime slurry stripped FRP piping in a flue gas desulfurization scrubber operating at 93°C. Coated in-situ with high-temperature ceramic composite — no piping replacement needed.
Belzona 1391Belzona 5891View KHIA →PDF ↓Belzona KHIA · 2005Case studies are from Belzona’s official Know-How in Action library (© Belzona International Ltd), shared here by S.A. International as authorized distributor. More Steel, Fertilizer and other industry cases are added regularly. For KHIAs matching your exact equipment, ask our engineers.
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