NESL Restores Ship’s Conduit Pipe and Junction Box with Belzona 1311 & Belzona 5811

admin — Mon, 07 Apr 2025 07:59:28 +0000

At NESL, we pride ourselves on delivering cutting-edge solutions to complex marine Enviornmental challenges. Recently, our team undertook a critical project to restore a severely corroded conduit pipe and junction box on a ship without any hot work at the location, showcasing our expertise in fabrication, repair, and advanced coating technologies. This case study highlights the step-by-step process we followed to bring this vital infrastructure back to peak performance, ensuring durability and reliability for our client.

The Challenge: Severe Corrosion Threatening Operational Integrity

During the initial inspection, our team identified profound corrosion in the ship’s junction boxes and conduit pipes. The condition of the junction boxes was compromised, with deeply corroded components posing a risk to the vessel’s electrical systems. The conduit pipe, a critical element for protecting wiring, had also suffered extensive damage. Left unaddressed, these issues could have led to operational downtime, safety hazards, and costly replacements.

Assessment and Preparation

The restoration began with a thorough assessment of the damage. After an initial cleaning of the deeply corroded conduit pipe, our technicians used power tooling to remove rust and debris, preparing the surface for repair. This meticulous preparation ensured a strong foundation for the subsequent steps.

Fabrication of New Components

To address the corrosion, NESL’s skilled engineers fabricated new flanges and covers from scratch. This process, carried out with precision in our state-of-the-art facilities, ensured that the replacement parts met the exact specifications required for the ship’s junction box system. The newly fabricated flanges were cold bonded to the junction boxes using Belzona 1311, a high-performance epoxy-based composite known for its exceptional adhesion and durability.

Repairing Profound Damages

The corroded flange and cover were removed, and repairs commenced immediately. Using Belzona 1311, our team expertly repaired profound damages to the conduit pipe and junction box. This advanced material not only restored structural integrity but also provided long-term resistance to future corrosion.

Protective Coating Application

To safeguard the restored components, we coated the flanges with Belzona 5811, an industrial-grade protective coating designed to withstand harsh marine environments. The final wrapping and coating were completed using Belzona 5811 in conjunction with reinforcement tape, ensuring a robust barrier against moisture, salt, and other corrosive elements.

Final Inspection and Results

The project concluded with an aerial view of the restoration, showcasing the seamless integration of the repaired and newly fabricated components. The conduit pipe and junction box were fully restored, exceeding industry standards for reliability and longevity. Our client was thrilled with the outcome, confident in the enhanced performance and extended lifespan of their ship’s infrastructure.

Why NESL?

This project exemplifies NESL’s commitment to excellence. By combining advanced materials like Belzona 1311 and 5811 with our expertise in fabrication and repair, we delivered a solution that not only addressed immediate concerns but also provided lasting value. Our ability to tackle complex challenges with innovative techniques sets us apart as a trusted partner in industrial restoration.

Thank You for Your Trust

We extend our gratitude to our valued client for entrusting us with this critical project. At NESL, we’re dedicated to pushing the boundaries of what’s possible, ensuring that every job—big or small—is completed with precision, care, and a focus on customer satisfaction.

Belzona 5811 Protects Electrical Control Panel in Brewery Unit

admin — Tue, 27 Feb 2024 07:25:45 +0000

A prominent brewery unit in India was facing corrosion damage to its electrical control panel due to exposure to fumes. The corrosive environment had caused deterioration, risking the functionality and safety of the control panel.

Belzona Solution:

To address the corrosion issue, our Belzona Team recommended the use of Belzona 5811.

Belzona 5811 – Is a 2-part epoxy coating which provides outstanding chemical resistance and protects equipment operating under immersion in aqueous solutions up to 50°C (122°F) from the effects of corrosion. This solvent-free material can be easily applied by brush or spray to virtually any metallic and non-metallic surface, simplifying maintenance works.

Surface Preparation Procedure:

Cleaning: The surface of the control panel was thoroughly cleaned to remove any dirt, grease, or other contaminants using a suitable cleaner.

Abrasive Blasting: Abrasive blasting was performed to achieve a surface cleanliness of at least Sa 2.5 (ISO 8501-1). The surface profile was measured to ensure it met the required roughness for optimal coating adhesion.

Masking The Switches and Other Control Devices: Any areas not to be coated were carefully masked off to prevent overcoat. (See the picture above)

The Application: Two coats of Belzona 5811 was applied to the prepared surface using a soft bristled brush and roller, ensuring a uniform and adequate thickness. First coat was left for 2 hours before the second coat was applied.

Curing Time: The coating was allowed to cure at room temperature for the specified time to achieve full strength and chemical resistance. The curing time for Belzona 5811 depends on the ambient temperature and thickness of the coating. It took 24 hours to achieve full cure at room temperature.

Reinspection Result:

The control panel was re-inspected after a year and found to be in perfect working condition without showing any signs of corrosion or coating degradation.

Belzona 5811 – NICCO ENGINEERING SERVICES LIMITED

NESL Restores Ship’s Conduit Pipe and Junction Box with Belzona 1311 & Belzona 5811

Belzona 5811 Protects Electrical Control Panel in Brewery Unit