Maintenance Solutions
FOR HVAC SYSTEMS
Belzona Protective Coatings and Engineering Composites
NOVEL SOLUTIONS TO AGE-OLD PROBLEMS
As a result of over 60 years of continuous development, Belzona provides a complete range of innovative,
proven repair and protection systems for common problems affecting HVAC equipment. Our polymeric
repair composites and protective coatings have stood the test of time by providing high performance
solutions which are proven to last, helping clients to:
• Reduce downtime • Improve efficiency and safety
• Extend equipment and asset life • Simplify maintenance procedures
• Reduce capital expenditure • Lower maintenance costs
Our unique solutions are engineered to withstand the most aggressive environments and operating
conditions, such as erosion, corrosion, chemical attack and mechanical damage. We take pride in the quality
of our materials as well as the comprehensive training and field support we provide to ensure the highest
possible application standards.
Company established, First corrosion Insulation protection Efficiency Heat activated corrosion
offering zinc-rich anti- resistant steel alloy membrane introduced enhancement under insulation repair
corrosive coatings applied coatings introduced materials introduced
1950 1960 1970 1980 1990 2000 2010
First cold-curing Elastomeric material First elastomer Sprayable erosion
Metallic Polymers development for rubber repair resistant linings
BELZONA introduced materials introduced developed
Timeline
Global application standards
Prequalification
Belzona materials are subject to stringent independent and in-house testing,
documented in the product specification sheets and chemical resistance
charts. Testing is performed in our ISO 9001 audited laboratory to recognised
standards, including ASTM, ISO and NACE, as well as by independant
organisations. Belzona products are approved by classification societies and
companies from all around the world, including Lloyds Register, DNV GL, ABS,
CCS, RS, KR, WRAS, Bureau Veritas, NSF and Nato, among others.
SPECIFICATION
Optimum materials and application procedures are selected to meet the
specific design and operating conditions of the asset. Dedicated Belzona
trained specialists coupled with round the clock head office technical support
allow for the correct material and application procedure to be specified. We
also maintain a comprehensive database accessible by the Global Belzona
Distributor network, which facilitates sharing of information and experience,
improving specification and application standards.
Application
Application standards, including surface preparation, are integral to the success
and longevity of the repair solution. Belzona recognises the need to set and
monitor global standards for the application of our materials. Applications
are carried out by experienced and trained personnel. Belzona runs training
programmes with theoretical and practical courses, including validated training.
Combined with method statements, quality control procedures and daily
inspection reports, we strive to ensure application standards are maintained
around the world.
INSPECTION
Inspection can be carried out by certified inspectors (e.g. NACE) prior to,
during and upon completion of the application to ensure Belzona systems are
applied in accordance with our standards and the client’s requirements.
Upon nearing the end of the system’s expected service life, the asset should
be inspected again and appropriate action recommended, which may involve
minor repair work or no action, as the Belzona systems tend to outlast
projected service life.
Belzona solutions for hvac
PROBLEMS IN HVAC SYSTEMS BELZONA POLYMERIC SOLUTIONS
Heating, Ventilation and Air Conditioning As a vital part of any large building, heating and
(HVAC) is essential in many industrial situations air conditioning equipment needs to be regularly
and is vital for maintaining a satisfactory maintained to ensure it is able to operate 24/7. In
working environment in large commercial Belzona, we recognise the need for a fully operational
facilities, sporting and entertainment stadia, HVAC system and offer an array of maintenance
theatres, hospitals and other public locations. solutions to repair and combat the typical problems
related to HVAC systems.
Corrosion is usually a major battle for building
owners and managers to maintain the Belzona paste grade composites rebuild the surfaces
integrity of a HVAC system. If the issues are damaged by corrosion, erosion, chemical attack or
left untreated, there is a high probability of wear, while the coating grade materials provide a
environmental and safety hazards, incidents protective layer against future degradation. These
and high replacement costs. Corrosion damage polymeric materials stop corrosion from reoccurring,
to components of the HVAC units can impact ensuring a durable repair and long-term protection.
the overall efficiency, cost and longevity of the With a cold and simple application, Belzona solutions
HVAC system. allow for a rapid return to service, reducing downtime
to a minimum and avoiding costly replacement.
Why Belzona?
Belzona coatings and repair systems are used throughout the
world to ensure that HVAC systems continue to run with minimal
disruption. Belzona’s composites combine easy and safe application
with outstanding mechanical properties. Our versatile product range
provides varied working times, cure times, temperature ranges
and degrees of required surface preparation. Belzona’s polymeric
technology offers combination of application and in-service
performance benefits rarely found in alternative solutions:
Repair and protection of condenser water
systems
Cold applied - no hot work
Solvent free - safe application even in confined spaces
Simple application procedure - no specialist tools required
Excellent adhesion to metals and other substrates
Our range of solutions for HVAC equipment can solve many common
maintenance problems including chiller corrosion, leaks in pipework
and ductwork, fan erosion-corrosion, damaged thermal insulation, and
poor weatherproofing and waterproofing of roof locations and service
voids. The key areas of application of Belzona within HVAC are:
Solutions for chilled water systems
Corrosion protection of Protection of insulation
internal surfaces and external surfaces
Rebuilding and resurfacing Sealing of joints and
of metallic surfaces seams
Repair of mechanical Erosion protection of
elements such as shafts fan blades
Protection against air and water ingress into
ductwork
Repair and Protection of Condenser
Water Systems
Corrosion in cooling towers Corrosion and chemical attack
Chemical treated water accelerates consumption of zinc
In areas with a hot climate, large office buildings, hospitals, galvanizing leading to premature corrosion.
and schools typically use one or more cooling towers as
part of their air conditioning systems. Unlike the large Erosion by impingement
concrete units at power stations, these smaller cooling Fan blade leading edges are frequently damaged by
towers are commonly constructed from galvanized steel impingement from air particles, causing erosion-corrosion.
and over time suffer from corrosion.
Mechanical damage
The combination of air, water, chemicals and heat in Poor maintenance such as lack of bearing lubrication, loose
cooling towers creates a severe corrosive environment. pulleys and fan hubs results in scored and worn fan shafts.
It is common to find perforations and holes and severe
metal loss on units in service. In addition, cooling tower fan Aging of the unit and failure of original coatings
blades usually suffer from erosion of the leading edge, as Poorly specified paint systems fail to protect in warm, humid
well as cracks and flaking on the trailing edge, reducing the and immersed environments, which can result in legionaires
overall efficiency of the system. disease outbreaks.
Belzona solutions
Cooling towers are often a neglected part of the system Belzona’s polymeric corrosion resistant coatings and cold-
and when located on the roof, they can be difficult to applied metal repair composites are engineered for the
maintain, repair or replace. harsh conditions inside cooling tower systems, providing
durable protection against corrosion and chemical attack,
Belzona’s materials can deal with numerous maintenance
as well as erosion and wear. Pitting corrosion and metal
problems in cooling towers including corrosion of internal
loss can be recovered without the need of welding,
surfaces, erosion-corrosion of fan blades, worn fan shafts
avoiding expensive replacement costs. Our solutions
and leaking pipework, extending maintenance-free
can be used to repair damaged units, or applied to new
periods.
equipment to significantly extend its life in service.
application areas
Corrosion and chemical protection of internal surfaces Belzona 5800 Series
Sealing of joints (internal and external) Belzona 3100 Series and Belzona 2000 Series
Plate bonding on cooling tower structure Belzona 1100 Series and Belzona 1200 Series
Pipe leak sealing Belzona 1100 Series and Belzona 1200 Series
Repair and protection of fan blades Belzona 1300 Series
Fan shaft repair (using forming techniques) Belzona 1100 Series and Belzona 1200 Series
Repair and
protection of fan
blades
Sealing of cooling
towers joints and
seams
Sealing of pipe
leaks
Corrosion protection
on cooling tower
*For further information and advice please contact your local Belzona representative.
basins and sidewalls
BEFORE
Solutions for
Chilled Water
SystemS
Chillers deterioration
Shell and tube heat exchangers, also referred to
as a chillers, are a vital part of any heating or air
conditioning system. Failure to quickly protect these
units allows galvanic corrosion to take place, resulting
in wastage and metal loss on the tube sheet around
the coolant tubes.
Left untreated, the loss of metal can cause leakage of
the coolant and contamination of the chilled water.
Corrosion is not restricted to the tube sheet, the water
box and end covers can also be affected. In particular,
corrosion in division bars and seal faces can lead to
leakage and loss of efficiency, as well as the inability to
maintain the desired working environment in buildings.
A corrosion allowance is designed to accept
anticipated levels of metal loss. However, throughout
lifetime, metal losses will gradually occur, primarily
due to galvanic corrosion. If the corrosion allowance
is exceeded and gaps appear, recirculation can occur,
leading to efficiency loss. In addition, the processed
fluid can erode the metal further, accelerating
degradation if corrosion is already present.
Galvanic corrosion
After Crevice corrosion
Erosion
Chemical attack
Belzona SolutionS Belzona materials
The affected section is rebuilt using Belzona’s two-component Belzona 1100 Series
repair composites. The paste grade material rebuilds the substrate
Paste grade rebuilding and resurfacing materials
to its original tolerances, while the coating grade system provides
for in-situ repair and rebuilding for damaged tube
a layer of durable protection. This cold-applied repair process
sheets prior to the application of a long-lasting
bypasses the need of hot work that would leave the substrate
protective coating.
susceptible to further damage.
Belzona 1200 Series
Belzona polymeric technology isolates the dissimilar metals,
Fast curing emergency paste grade rebuilding
preventing further galvanic corrosion. The tough repair and coating
and resurfacing materials for the rapid repair of
system also protects the chiller against the effects of erosion
metallic parts.
and, as a result, increases asset life and efficiency while avoiding
replacement. Belzona materials are easy and quick to apply by
Belzona 1300 Series
hand, reducing downtime and hazards during application.
Ceramic filled and high molecular weight polymer
The Belzona solution not only restores the original tube sheet coatings and rebuilding materials to stop galvanic
profile, but also creates a smooth tube sheet face flush with the corrosion and significantly slow down erosion,
tube ends, leading to reduced turbulence and greater efficiency. reducing expenses associated with repairs or
Water boxes and end covers can also be repaired and protected. replacement.
repair of erosion-corrosion damage in tube sheets
1. 2. 3. 4.
Surface preparation Insertion of corks Surface rebuilding Completed application
The corroded surface is prepared The tubes are blocked off The Belzona material is applied The Belzona coating provides
by grit-blasting and washed with tapered corks. The corks to all eroded areas using an complete protection against
with Belzona 9111 to remove all are levelled using the most applicator to restore the original the effects of erosion-corrosion
residual blasting debris. protruding tube as a guide. profile. and outstanding resistance to
chemicals.
Protection against AIR AND WATER
INGRESS INTO DUCTWORK
AIR SYSTEM MAINTENANCE CHALLENGES Corrosion of internal surfaces
From internal corrosion, accelerated by water condensation,
high temperatures, aggressive cleaning chemicals and Metal loss leading to thin-wall and
microbiological growth, to the failure of joints and seams, through-wall metal defects
maintenance of air handlers and ductwork can prove
challenging. Condensation weakens and corrodes the metal of Internal microbiological growth
the ducts, which can lead to air leaks and water ingress, and
subsequent efficiency losses and operational failure.
Deterioration of joints and seams
Belzona recognises the challenges of air system maintenance
and addresses them with the development of cold-applied Air leaks and water ingress
polymeric repair materials and corrosion resistant coatings
designed to function in these severe operating conditions. Corrosion under insulation
BELZONA Solutions
Metal loss repair Corrosion and weathering Joint and seam sealing
Corrosion of surfaces such as condensate protection Failure of joints and seams can allow critical
drip pans, cooling coil supports and The coating of interior air handler ingress of water and disruption of air flow,
ductwork can cause significant metal loss, parts and ductwork prevents future affecting the cooling and heating process.
leading to thin-wall and even through- corrosion, avoiding premature failure and Belzona’s flexible repair materials can
wall defects. Belzona‘s metal repair replacement. In addition, encapsulation restore joints and seams as a long-lasting
materials offer a cold-applied alternative provides seamless protection at ductwork solution. Sealing at the interface between
to replacement or unwanted hot work elbows, T-pieces and complex contours. the roof and the ductwork can also be
repairs. achieved with Belzona flexible membranes.
Belzona 1100 Series Belzona 5800 Series Belzona 2000 Series
Multi-purpose composite repair Solvent-free internal coatings for Flexible, durable elastomers used to
materials for the rebuilding and excellent corrosion protection and restore deteriorated joints and seams,
resurfacing of metal surfaces, or for engineered for the harsh environment whilst accommodating for movement
metal plate bonding. inside the HVAC system. between sections.
Belzona 1200 Series Belzona 3000 Series Belzona 3000 Series
Fast-curing repair materials for Liquid-applied flexible membranes for Liquid-applied flexible membranes for
rapid repair and rebuilding of metal insulation encapsulation, providing a effective sealing of the roof-ductwork
substrates, even with minimal surface barrier against corrosion that can be interface.
preparation and wet surface. cut open and resealed for periodic
inspection.
The Belzona App
Product and application information at your fingertips
Once installed, access materials offline:
• Product information • Instructions for use
• Industry solutions • Chemical resistance charts
• Technical documentation • Videos
Download now
www.belzona.com/app
ISO 9001:2008
Q 09335
ISO 14001:2004
EMS 509612
Belzona products are manufactured
under an ISO 9000 Registered Quality
Management System UK • USA • Canada • Thailand • China
www.belzona.com
Copyright © Belzona International Limited 2016 ZCORPHVAC(E)07/16
