Tube Sheets | Channel Heads | Shells | Baffles
Heat Exchanger Repair
Rebuild eroded and corroded heat exchanger components in place. Extend service life without the cost and lead time of replacement.
Why Heat Exchangers Fail
Heat exchangers operate in demanding conditions — high temperatures, corrosive fluids, and constant thermal cycling. Over time, tube sheets erode around tube ends, channel heads corrode from cooling water, and shells deteriorate from process chemicals.
Traditional repair means removing the exchanger, shipping it to a shop, and waiting weeks for machining or replacement parts. Belzona repair composites and coatings allow in-place rebuilding during scheduled turnarounds, often returning equipment to service in days rather than weeks.
Different damage requires different solutions. Erosion around tube ends needs high-strength rebuilding composites. Corrosion protection requires chemical-resistant coatings. High-temperature service demands specialized materials rated for continuous heat exposure.
Repair vs Replace
Traditional Replacement
6-12 week lead time
Custom fabrication, shipping, scheduling
Equipment removal required
Rigging, transportation, reinstallation
High capital cost
New components, labor, extended downtime
Same failure will recur
New metal exposed to same conditions
Belzona In-Place Repair
Completed during turnaround
Days, not weeks — fits scheduled maintenance
Repair in place
No removal, no rigging, no transport
Fraction of replacement cost
Materials and labor vs. new equipment
Protection against future damage
Coatings prevent recurrence of corrosion
Rebuilding Composites
High-strength epoxy composites for rebuilding eroded tube sheets, worn channel heads, and damaged shells.
Super Metal
General purpose metal repair paste. Excellent for rebuilding eroded tube sheets and restoring dimensions on channel heads.
Service temp: Up to 80°C (176°F)
Best for: General rebuilding, erosion repair
Ceramic R-Metal
Ceramic-reinforced composite with superior erosion and corrosion resistance. Ideal for severe service conditions.
Service temp: Up to 80°C (176°F)
Best for: Erosion-corrosion, abrasive service
Super HT-Metal
High-temperature repair composite for rebuilding components in elevated temperature service.
Service temp: Up to 150°C (302°F)
Best for: High-temp exchangers, steam service
Protective Coatings
After rebuilding, protect surfaces from future corrosion and erosion with chemical-resistant coatings matched to your service conditions.
Ceramic S-Metal
Solvent-free ceramic coating for protection against erosion, corrosion, and chemical attack.
Service temp: Up to 60°C (140°F) immersion
Best for: Cooling water, mild chemicals
Supermetalglide
Low-friction, erosion-resistant coating that improves flow characteristics while protecting surfaces.
Service temp: Up to 60°C (140°F) immersion
Best for: Slurries, abrasive flow, efficiency
HTS
High-temperature spray coating for protecting surfaces in continuous high-heat service.
Service temp: Up to 160°C (320°F)
Best for: High-temp protection, steam
HIGH-TEMPERATURE SERVICE
Repair and Protection Above 80°C
Super HT-Metal
High-temperature repair composite for rebuilding eroded and corroded surfaces on heat exchangers operating above standard epoxy limits.
- Service temperature up to 150°C (302°F)
- Excellent chemical resistance
- Rebuild tube sheets and channel heads
- Cold-applied — no hot work required
HTS Coating
High-temperature spray coating for long-term protection of heat exchanger internals in elevated temperature and chemical environments.
- Service temperature up to 160°C (320°F)
- Superior abrasion resistance
- Spray applied for fast coverage
- Broad chemical resistance
Common Applications
Tube Sheet Erosion
Rebuild eroded areas around tube ends and restore sealing surfaces
Channel Head Corrosion
Repair cooling water corrosion damage and protect against recurrence
Shell Deterioration
Restore corroded shell internals and apply protective linings
Baffle Plate Damage
Rebuild worn baffle edges and restore flow distribution
Nozzle and Flange Repair
Restore corroded nozzle internals and damaged flange faces
Impingement Protection
Apply erosion-resistant coatings to inlet areas and impingement zones
Case Study
Chiller Tube Sheet Repair — Downtown Seattle
A downtown Seattle office building needed its chiller tube sheets rebuilt — 15 stories up, in a confined mechanical room accessible only by elevator. Replacing the unit was not an option. Removing it from the building was not practical. The facility needed a solution that could be carried in by hand and applied on the spot.
The Problem
Years of galvanic corrosion had severely eroded the chiller tube sheets, compromising seal integrity and reducing cooling efficiency. The mechanical room sat 15 stories above street level with elevator-only access — no crane, no rigging, no way to remove the equipment.
The Solution
Belzona 1311 (Ceramic R-Metal) was hand-applied to rebuild the eroded tube sheet profiles back to original dimensions. Two coats of Belzona 1321 (Ceramic S-Metal) were then applied as a protective barrier against future corrosion. All materials were carried up by elevator and applied cold — no hot work, no welding, no heavy equipment.
The Result
The chiller was returned to full service without ever leaving the mechanical room. The building avoided the cost and disruption of a full replacement, and the ceramic coating system now protects the tube sheets from the corrosion that caused the original failure.
Industries We Serve
Facilities Maintenance
HVAC exchangers, chillers, and building system heat transfer equipment.
Marine
Seawater coolers, lube oil coolers, and shipboard heat exchangers.
Oil and Gas
Process exchangers, fin-fan coolers, and refinery heat transfer equipment.
Pulp and Paper
Black liquor heaters, blow heat exchangers, and mill process coolers.
Mining
Process coolers handling abrasive slurries and corrosive leach solutions.
Chemical Processing
Process exchangers exposed to aggressive chemicals and high temperatures.
Frequently Asked Questions
Can you repair a heat exchanger without removing it?
Yes. Channel heads and accessible tube sheets can be repaired in place. The exchanger is opened, cleaned, and repaired during a scheduled turnaround without removal from the piping system.
What temperature can Belzona repairs withstand?
Standard composites like Belzona 1111 are rated to 80°C (176°F). High-temperature products like Belzona 1511 and 1593 are rated for continuous service up to 150-160°C (302-320°F).
How long does a typical repair take?
Most repairs are completed in 24-48 hours including cure time. Surface preparation, application, and initial cure can often be completed in a single turnaround window.
Will the repair last as long as new metal?
Belzona repairs with proper protective coatings often outlast the original metal because the coating prevents the corrosion that caused the original damage. Documented repairs have lasted 35+ years in service.
Can a heat exchanger be repaired instead of replaced?
Yes. Epoxy composites can rebuild tube sheets and restore structural integrity without the lead time or cost of replacement. For most corrosion and erosion damage, repair is the more practical option.
What causes tube sheet corrosion in heat exchangers?
Galvanic (electrolytic) corrosion between dissimilar metals is the primary cause, especially around coolant tubes. Chemical attack, thermal stress from temperature cycling, and erosion from fluid flow also contribute.
What are the signs of a damaged heat exchanger?
Reduced efficiency, fluid leaks, unusual noises, and visible corrosion on the tube sheet. Contamination of the chilled water from coolant leakage is a clear indicator of tube sheet damage.
How long does a heat exchanger repair last?
With proper surface preparation and protective coatings, repairs can extend heat exchanger life for many years. Documented Belzona repairs have lasted 35+ years in continuous service.
Need Heat Exchanger Repair?
Describe your damage and service conditions. We will recommend the right repair composite and coating system, provide product training, and support your turnaround throughout Washington, Oregon, Alaska, and Northern Idaho.
Belzona Technology Northwest is the exclusive authorized Belzona distributor for Washington, Oregon, Alaska, and Northern Idaho. Heat exchanger repair composites, protective coatings, and technical support for industrial facilities throughout the Pacific Northwest.