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Heat Exchanger
Repair & Protection

  • Rebuild tube sheets, water boxes, channel heads, & end covers
  • Isolate dissimilar metals to stop galvanic corrosion
  • Seal leaks in situ — no re-tubing or hot work
The Challenge

Heat exchangers combine dissimilar metals, high flow rates, and aggressive cooling media — a recipe for galvanic corrosion, erosion, and leaks at tube sheets and water boxes. As the metal degrades, tubes leak, efficiency drops, and the risk of cross-contamination rises. Re-tubing and component replacement are expensive and slow, and welding on thin tube sheets is difficult and risky.

A Real Rumford Example
Corroding Heat Exchanger Before
The Problem
Corroding Heat Exchanger

Dissimilar metals and aggressive cooling water were driving electrolytic corrosion through the water box and tube sheet.

  • ProblemElectrolysis & Corrosion
  • ResultOngoing Metal Loss
  • RiskPremature Failure
Hover for Belzona repair →
Coated & Protected — Belzona After — Belzona
The Solution
Coated & Protected — Belzona

Pitting rebuilt and the water box and tube sheet coated with Belzona — an insulating barrier that stops electrolysis and protects the metal.

  • Belzona CoatingInsulating Barrier
  • ElectrolysisEliminated
  • CorrosionStopped
The Belzona coating acts as an insulator — eliminating electrolysis and stopping corrosion.

Read the full case history →

A real Rumford Industrial Group project using Belzona solutions. Actual results vary by equipment, damage extent, and site conditions — contact us for a project-specific estimate.

Tube sheets, water boxes, channel heads, end covers, and divider plates corrode and erode where turbulent, often chemically treated water meets dissimilar metals. Galvanic activity between tubes and tube sheet accelerates attack, and leaking tube-to-tube-sheet joints let media bypass or mix.

Belzona coatings and repair composites rebuild lost metal, seal leaking joints, and — because they are electrical insulators — isolate dissimilar metals to break the galvanic cell. Applied in situ by Rumford Industrial Group, they restore performance and extend service life without full component replacement.

Belzona Solutions for This Application
Component Rebuilding & Profile Restoration
Cold-applied metal repair composites rebuild tube sheets, flange faces, water boxes, and end covers back to their original profile, including areas damaged by erosion and corrosion.
Galvanic & Crevice Corrosion Prevention
Materials act as electrical insulators to isolate dissimilar metals, eliminating galvanic corrosion and preventing crevice corrosion between components.
Erosion & Corrosion Protective Coatings
Epoxy coatings applied over repaired metal provide long-term erosion and corrosion resistance, including for continuous immersion service.
High-Temperature & Specialty Performance Coatings
Coatings and repair materials engineered for elevated service temperatures (up to 160°C/320°F) and specialty needs like chemical resistance, cavitation resistance, or efficiency enhancement.
What Belzona Can Do for Heat Exchangers
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Repair eroded – corroded tube sheets
Fill pitting and rebuild eroded tube-sheet faces to reinstate a sound, sealing surface without re-tubing.
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Rebuild damaged water boxes, end covers & channels
Restore lost wall thickness and original profile on water boxes, channel heads, covers, and divider plates.
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Apply erosion – corrosion resistant coatings
Line waterside surfaces with ceramic-filled coatings that resist turbulent, chemically treated cooling media.
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Repair existing linings
Patch and blend into damaged or disbonded linings during a short outage instead of stripping the whole unit.
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Seal leaks in heat exchangers
Seal weeping tube-to-tube-sheet joints, channel heads, and gasket faces in situ with no welding.
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Repair damaged cooling tower components
Rebuild and coat basins, distribution pipework, and structural components attacked by treated water.
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Protect and seal porous surfaces
Seal porous castings and concrete substrates to stop weeping and moisture ingress before coating.
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Protect insulation
Seal cladding and lagging to keep water out and prevent corrosion under insulation on exchanger pipework.
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Repair leaking pipework
Arrest live leaks and rebuild wall loss on associated cooling and process lines with composite wraps.
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Repair fan blades
Rebuild eroded cooling-fan blades and apply smooth coatings to recover airflow efficiency and balance.
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Repair damaged fan shafts
Rebuild worn shaft seats, keyways, and bearing journals back to correct dimensions on-site.
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Protect supporting steelwork against environmental erosion
Coat frames, supports, and walkways exposed to drift, humidity, and chemical carryover.
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Rebuild expansion joints
Rebuild and re-coat flexible joints with elastomer repair materials to restore movement and integrity.
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Seal expansion joints
Seal splits and leak paths in expansion joints and bellows without removing them from service position.
See it on our interactive Solution Maps

Explore how heat exchangers and cooling systems are protected and repaired in Belzona's interactive industry maps.

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