Innovative Cold Repair Solution for Marine Industry

admin — Thu, 05 Sep 2024 08:26:15 +0000

A renowned entertainment and hospitality group faced a significant challenge when severe pitting was discovered on the hull of their 90-meter-long casino ship. The ship had been in continuous operation in water for six years, making maintenance difficult. The cause of the problem was identified as broken anodes, which led to over 2000 pits on the ship’s surface.

Problem

The ship’s pitted hull posed a serious risk to its structural integrity and operational safety. Traditional repair methods, such as welding and replacement, were considered but deemed impractical due to their high cost, lengthy downtime, and logistical difficulties associated with ship maintenance. As the casino ship is a revenue-generating asset, minimizing downtime was crucial.

Inspection and Findings

Nicco service engineers conducted a thorough inspection and confirmed the severity of the damage. The inspection revealed:

Over 2000 pits of varying sizes on the ship’s hull.
Extensive damage caused by electrochemical reactions due to the failure of the anodes.
The compromised state of the ship’s protective coating, which left the underlying metal vulnerable to further corrosion.
Traditional repair method like welding was not possible on the Fuel tank of the ship.

Solution: Cold Repair with Belzona Composites

Given the constraints, Nicco engineers proposed a cold repair solution using Belzona coatings and repair composites, which offer a fast, durable, and cost-effective alternative to conventional methods. The recommendation focused on using:

Belzona 1111 (Super Metal): An epoxy-based composite material designed for metal repair, Belzona 1111 was chosen to fill and rebuild the pitted areas of the hull. Its high adhesive properties and mechanical strength make it ideal for such applications.
Belzona 1121 (Super XL-Metal): Belzona 1121 provided additional protection against further corrosion, enhancing the longevity of the repair.

Application Process

The repair was carried out in accordance with the Belzona Know-How System, ensuring adherence to the highest industry standards. The process included:

Surface Preparation: The damaged areas were cleaned and prepared to ensure maximum adhesion of the Belzona materials. This included removing any loose debris, contaminants, and preparing the surface for the composite.
Application of Belzona 1111: The Belzona 1111 composite was applied to the pitted areas to rebuild the hull’s surface. Its excellent bonding properties allowed it to adhere firmly to the prepared surface, effectively filling and covering the pits.
Application of Belzona 1121: Once the Belzona 1111 cured, Belzona 1121 was applied to provide an additional layer of protection, ensuring the repaired areas would withstand future exposure to water and corrosion.

Key Advantages of Belzona Cold Repair Solution

The cold repair solution provided immediate and long-lasting results. Key outcomes included:

Minimal Downtime: The quick application process minimized downtime, allowing the casino ship to return to service promptly.
Cost Efficiency: Compared to conventional repair methods, the cold repair approach significantly reduced repair costs and avoided extensive dry-docking expenses.
Enhanced Durability: The Belzona coatings not only repaired the pits but also offered improved resistance against future corrosion, extending the operational life of the ship’s hull.

Marine Industry – NICCO ENGINEERING SERVICES LIMITED

Innovative Cold Repair Solution for Marine Industry