Belzona Seals Persistent Cooling Tower Leak at Outlet Pipe Interface
A cooling tower at a leading industrial gas producing facility in India had developed a profuse leakage at the peripheral junction of the concrete wall and the outlet pipe section. The ongoing leakage created a maintenance concern for the plant and required a practical sealing solution that could be applied effectively on site.
The application was carried out in 2025 for an industrial gas producing facility asset with a concrete & metal substrate.
The Challenge
Leakage had been observed on the cooling tower wall throughout the periphery of the outlet pipe section, indicating a failure at the interface between the pipe and the surrounding concrete. Left unresolved, this type of leak can continue to undermine asset condition and leads to plant shutdown. Plant engineers needed a reliable, long-term repair approach that would address the leak without resorting to more disruptive remedial work followed by wrapping of the metal pipeline which was thinned out as well.
The Belzona Solution
Working closely with plant engineers, our Belzona sales engineer recommended a repair strategy using Belzona 4211 in combination with Belzona 4111 (Magma Quartz) for leakage arresting & Belzona 1161- Super UW Metal in conjunction with Belzona –9341 Reinforcement Tape for pipe surface restoration. The system was selected to seal the gap between the pipe and the concrete and create a durable protective layer over the repaired area.
Application Method
The repair was completed in accordance with Belzona Know-How System Leaflets TCC-9. Surface preparation began with chipping off the loose mortor of the concrete followed by manual abrading to ensure the area was properly prepared for application. The cracks and gap between the pipe and concrete were then sealed using Belzona 4211. Once this had been forced into the void, Belzona 4111 was applied over the treated area to complete the repair and provide a robust sealed finish.
Visual Repair Progress
The project photographs show the progression of the repair from visible leakage on the cooling tower wall near the outlet pipe section, through the insertion of Belzona 4211 into the gap, to the final over-application of Belzona 4111 across the repaired area. The completed repair presents a sealed and uniform finish around the pipe interface.
Result
By combining effective surface preparation with a proven Belzona sealing system, the plant was able to address a long-term leak at a critical cooling tower location. The repair delivered a practical in-situ solution and demonstrated how Belzona materials can be used to restore integrity and improve reliability in concrete cooling tower structures.
