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Cold Bonding Solution

Corroded Beam Reinforcement
in Gas Separation Plant

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Corroded Beam Reinforcement

Case Study
Major Petrochemical Plant , Rayong , Thailand
Severe corrosion and metal loss on Pipe rack beam
throughout the plant can lead to Pipe rack collapse
and serious accident.

Corroded Beam Reinforcement

Case Study

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The corrosion was caused by crack cementitiousfireproof .

The corrosion hided under thick fireproof paint and
was not detected by visual inspection.
Inspection in 2007 was decided to remove crack
fireproof paint for inspection

Pipe rack beam arrangement

Corroded Beam Reinforcement

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Corrosion on Beam after Grit blast to remove Fireproof paint

Corroded Beam Reinforcement

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Cause of corrosion was the result of cementitious fireproof

Cracking & deterioration.

Typical arrangement of Cementitioius fireproof on Beam

Corroded Beam Reinforcement

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SOLUTION :
Severe metal loss raised concern about Beam
strength and integrity.
External Engineering specialist was contacted by
client to verify the Beam strength and they
recommended to reinstate the Beam.
Available solutions were
1. Replace the new Beam
2. Hot Welding to reinstate the Beam
3. Cold Bonding to reinstate the Beam

Corroded Beam Reinforcement

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SOLUTION :
Available solutions
1. Replace the new Beam is not possible because ;
Pipe rack beam run throughout the plant
Complexity of Pipe rack arrangement
Some areas were hard to access
Very Expensive and Partial Plant shutdown required
2. Hot Welding to reinstate the Beam

Possible but too risky because the Beam was

supporting Hydrocarbon Pipeline

Many technical limitation for welding efficiency

Corroded Beam Reinforcement

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SOLUTION :
The Cold Repair by BELZONA Cold Bonding Method
was considered only the reasonable solution
Client requested us to do Load test to prove that
BELZONA Cold Bonding can reinstate the Beam
strength
Testing was agreed to carry out by Pan Mechanic and
Client

Corroded Beam Reinforcement

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TEST OBJECTIVE :
The test was carried out to calculate the Deflection
comparing between
1. Standard Beam
2. Defected Beam + Reinforced with Metal plate by
BELZONA Cold Bonding
the Item 2 shall provide equal or less deflection than
Item 1 when applied at the same load to prove that
Reinforced by Cold Bonding can reinstate the Beam
strength.

Corroded Beam Reinforcement

Case Study

TESTING : Load Test Table

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Corroded Beam Reinforcement

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TESTING : Beam Preparation

Beam and Reinforcement Plate

Belzona 1121 Super-XL Metal
(as Cold Bonding Material)

Corroded Beam Reinforcement

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TESTING : Beam Preparation

Cut of some of Beam surface to

Stimulate the corrosion/metal loss

Corroded Beam Reinforcement

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TESTING : Beam Preparation

Grit Blast the Beam /

Plate to SA2.5
roughness > 75 microns

Blasted Beam & Plate

Corroded Beam Reinforcement

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TESTING : Beam Preparation

Mix Belzona 1121 Super-XL Metal

Apply to the prepared area

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Corroded Beam Reinforcement

Case Study

TESTING : Beam Preparation

Put thickness shim 2mm on

the plate to control the
thickness of the Bonding

Bond the plate to prepared area

Corroded Beam Reinforcement

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TESTING : Beam Preparation

Leave the Plate to be cured , then remove the clamp

Corroded Beam Reinforcement

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TESTING : Beam Preparation

(Another Beam) Bond the plate underneath the bottom beam

Corroded Beam Reinforcement

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TESTING : Beam Preparation

Leave the Plate to be cured , then remove the clamp

Corroded Beam Reinforcement

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TESTING : Test Equipment

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Corroded Beam Reinforcement

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TESTING : Test Equipments

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Corroded Beam Reinforcement

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TESTING : Load & Deflection Calculation

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Corroded Beam Reinforcement

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TESTING : Load Test

Standard Beam Test , read dial gauge and pressure

gauge

Corroded Beam Reinforcement

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TESTING : Load Test

Reinforced Beam Test (Uniform / Point Load )

Corroded Beam Reinforcement

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TESTING : Load Test

Reinforced Beam Test (Uniform / Point Load ) , test until failure

Corroded Beam Reinforcement

Case Study
TEST
RESULT :

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Corroded Beam Reinforcement

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TEST
RESULT :

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Corroded Beam Reinforcement

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TESTING : Test Summary

1. Reinforced beam have less deflection
compared to the standard beam thus providing
more strength than standard beam.
2. From the calculation , the maximum
deflection of Standard Beam length 0.8 m. shall
not more than 1.32 mm. From the graph , at
1.32 mm deflection , all reinforced Beam will
provide more load bearing capability.
3. At 1.32 mm deflection , Belzona Bonding was
still adhere well to the Beam

Corroded Beam Reinforcement

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TESTING : Test Result

BELZONA Cold Bonding was selected as the repair
solution for the corroded beam
Material used :
Belzona 1121 Super-XL Metal approx 1,000 kg
Belzona 1121 will provide long working time to apply
on large metal plate.

Corroded Beam Reinforcement

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REPAIR APPLICATION

Beam and Reinforcement Plate were Grit blast to SA2.5 and

Roughness more than 75 microns

Corroded Beam Reinforcement

Case Study

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REPAIR APPLICATION

Beam and Reinforcement Plate were Grit blast to SA2.5 and

Roughness more than 75 microns

Corroded Beam Reinforcement

Case Study

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REPAIR APPLICATION

Belzona 1121 Super-XL Metal as bonding materials

Corroded Beam Reinforcement

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REPAIR APPLICATION

Apply Belzona 1121 on the reinforcement plate and Beam

Corroded Beam Reinforcement

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REPAIR APPLICATION

Put the 2 mm-thick washer on the plate as the shim

Corroded Beam Reinforcement

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REPAIR APPLICATION

Adhere the plate to the Beam securing with clamps

Corroded Beam Reinforcement

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REPAIR APPLICATION

Adhere the plate to the Beam securing with clamps

Corroded Beam Reinforcement

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REPAIR APPLICATION

Adhere the plate to the Beam securing with clamps

Corroded Beam Reinforcement

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REPAIR APPLICATION

Adhere the plate to the Beam securing with clamps

Leave the bonding material to cure for 2 hours before
removing the clamp.

Corroded Beam Reinforcement

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BENEFIT of BELZONA Cold Bonding

1. No Hot Work (Except Grit Blasting )
2. No partial plant shutdown
3. Short repair time
4. Economic

Corroded Beam Reinforcement

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LESSON LEARN FROM THIS CASE

1. Although not every cases , Cold Bonding Repair can
replace many conventional hot work in your plants with
comparable efficiency but less risk / less production
loss
2. Severe corrosion problem may hide in some places in
your plants such as under insulation , under damaged
fireproof system , under pipe support , under tank base ,
splash zone, underwateretc.
Inspection plan shall also focus on these invisible areas
apart from the general areas.