With a tried and tested history, high performance composite materials can provide the answer to protection against corrosion, erosion and chemical attack. They can eliminate hot works, minimise down-time, reduce expensive replacement costs and even improve efficiency and performance whilst increasing service life.
Composites can be used to tailor bespoke solutions to client specific needs throughout all industry, reclaiming and returning to duty items that otherwise would have been scrapped.
Metal Repair Solutions – applied to any metal type as high strength, solvent free, metallic filled epoxy paste grade or fluid grade base, dependant on the geometry or circumstances of the repair. Great for rebuilding corroded/eroded metallic substrates, such as cast pump bodies, impellers, worn flange faces or bearing housings, in fact any areas that require rebuild or repair to original substrate profile.
To eliminate hot works or welding it can also be used as a structural adhesive to apply steel patches on holed surfaces or to re-establish integrity to tanks or pipework, sometimes still while in service without the need to shut down or even underwater!
Once the above has been used and the area is back to profile, it is generally protected with a further coating designed or selected for the duty in which the finished item would be subjected too. This may be heavy abrasion or wear, high impact, elevated temperatures or concentrated chemical environments.
Repair possibilities or the process is not governed to just items that are metallic made, in fact there are composite polymeric solutions that cover repairs to rubber, GRP, concrete, super alloys and much more.
Grade 2 Impact can supply and apply the relevant products to suit any rebuild or repair required, reducing expensive replacement costs, increase service life, minimise down time and improve efficiency.
Our workshop caters for items that can be taken from site and systematically repaired in a controlled environment. We can however also attend site, should removal be restricted by size or logistics, undertaking all preparatory needs and apply suitable products for our client’s specific requirements.
Some of the items recently completed can be seen below.
Pumps and associated pumping equipment are used throught all sectors, from oil & gas to food & beverages and can suffer from erosion, corrosion, cavitation, chemical attack or a mixture of all in severe cases.
If left exposed and untreated within the process, the pump efficiency will deteriorate significantly, causing the following implications;
These costly effects can be easily prevented, even if the component looks like it is beyond repair - by application of cold applied, high performance composite products to all fluid handling components, rebuilding as necessary back to original profiles and applying further coatings to protect from the effects of erosion-corrosion.
This solution not only reclaims items otherwise scrapped, but also results in offering long term protection with additional benefits of improved efficiency, resulting in significantly reducing operating costs.
One of our waste water clients had 2 pumps in need of service and repair, one of which was taken off-line and inspected. It was found that the impeller was so badly eroded and corroded that the client instantly thought to replace with a new one, however the OEM leadtime to supply was over 2 months. This was not acceptable and Grade 2 Impact were approached to see if we could achieve a suitable repair so it could be returned to service as soon as possible.
Once completed and returned to our client within 4 days, it was put straight back to work within the serviced pump. Our client was so impressed with the outcome, that they sent us the second pump impeller to rebuild in the same way.
Grade 2 Impact are approved applicators of high performance composite products and able to reconstruct damaged items, undertake all substrate repairs and application of performance coatings.
We also undertake similar preparation and protective coatings work to all pump types, whether it is split casing double entry, vertical submersible multi stage bowl and liquid ring, plus chemical containment areas constructed from concrete, stone, brick or metals.
Pumps and associated pumping equipment are used throught all sectors, from oil & gas to food & beverages and are exposed to some of the most aggressive chemicals ever made, some of which are so severe that they chemically erode/corrode and attack the base materials used to manufacture the pump parts if left exposed and untreated within the process.
Some pumps are made from exotic alloys which provide excellent resistance and longevity, however are extremely costly to manufacture and purchase, plus can have extended foundry lead times.
In order to protect against this aggressive attack and ensure longevity in service, it is always best to apply an acid resistant lining or high performance chemical resistant coating from new, or if the process changes to a more acidic or strong alkali duty.
Acid resistant linings or chemical resistant coatings can be supplied and applied to the pump body, impeller and components at a reasonable cost to more affordable materials such as carbon steel or cast iron, compared to the costs of exotic alloy replacements, plus returned to service without major down time.
Regardless of material, prior to application of acid resistant linings or coatings, it may be necessary to re-build areas of degradation to the substrate brought on from chemical attack. This is achievable through use of composite repair materials to re-build back to original substrate profile prior to lining with a two component, solvent free barrier coating.
Grade 2 Impact can undertake all substrate repairs and application of resistant liners and coatings.
Below are some recent photographs of a cast bronze single stage, end suction pump that is being used for high concentration sulphuric acid. It has been repaired and lined using a high performance chemical resistant coating. Its excellent adhesion isolates the metalic surfaces from the aggressive chemicals, offering outstanding long term protection.
Please note that we also undertake similar preparation and protective coatings work to all pump types, whether it is split casing double entry, vertical submersible multi stage bowl and liquid ring, plus chemical containment areas constructed from concrete, stone, brick or metals.
Should you require any additional information regarding our services or would like a quotation for similar works, please do not hesitate to contact us.