In the heart of the Netherlands, two large tank farms chose cold bonding to face two daunting challenges: over 1100 brackets needed to be installed on live, fully operational tanks filled with highly flammable liquids. Traditional welding was impossible, as taking the site offline and emptying the vessels would have required a costly shutdown that was not a viable option. So, seeking a welding alternative, the customers chose Belzona’s innovative cold bonding solution.

The Problem

The first client, a global infrastructure provider, wished to make their operations more sustainable by installing solar panels on the top of their tanks. However, before the panels themselves could be implemented, cable ducts and supports needed to be installed across the entire structure. Such a large number of panels required around 500 brackets be cold bonded on to the live oil tanks, as hot work was out of the question.

The second client, a leader in tank terminal operations, required the installation of 660 brackets on to live kerosene tanks. This was required due to recent legislative changes that mandated the installation of extra fire extinguishing pipes. With safety as its top priority, the client sought a swift and dependable solution. It was crucial that the chosen method could install the required brackets without disrupting the facility's operations or incurring the unnecessary expense of a shutdown.                  

The Solution

For both sites, a hot work permit was out of the question and so a cold-bonding solution was required. The kerosene tanks were filled and had an internal coating, meaning hot work was not an option at the first site. Similarly, at the second site the tanks were fully operational, so a welding alternative was also required in this case.

Belzona offered a cold work solution that could be applied while the tanks were full and operational. Epoxy composite Belzona 1111 (Super Metal) was chosen for its high adhesion properties, as it can be applied and cured at ambient temperature using simple tools, which makes it ideal for this in-situ application. In addition to being less hazardous, this method also ensures greater contact across the surface area of the bonded bracket, compared to the limited contact of weld seams.

Application 

To begin with, the surface was suitably roughened to Swedish Standard Sa2½ (near white metal finish) with a 3 mil (75 μm) profile in order to achieve maximum adhesion. By utilizing ATEX closed-loop vacuum grit blasting, optimal surface preparation was achieved while mitigating the hazards of airborne grit and debris. This method not only ensured safety but also maintained operational continuity by eliminating the need for temporary structures like tents and additional scaffolding, which would have been required for conventional grit blasting. Therefore, the closed-loop system proved to be the most efficient solution for surface preparation on a live site.

Following completion of surface preparation, the team bonded the brackets onto the substrate using the selected epoxy composite. Once the product was mixed, a layer was firmly applied to the prepared surfaces of both the tank and the underside of each bracket. The brackets could then be pushed into place with force, secured, and left to cure.

Cold-Bonding Success

Both applications were successful, leaving the clients thrilled that the brackets had been securely installed without the need for welding, thereby avoiding the expenses and hazards associated with a costly shutdown or dangerous hot work.

The first client has successfully installed its solar panels after cold bonding over 500 brackets with the epoxy composite. This application was imperative to its successful implementation, helping the customer achieve its sustainability goals. Similarly, the second client is now fully compliant with the new fire safety regulations. In each case, choosing Belzona as a welding alternative allowed for a safe and efficient installation, without the need for hot work.

Established in 1952, Belzona designs and manufacturers polymer repair composites and industrial protective coatings. Learn more about Belzona at www.belzona.com.