Latest Case Studies & White Papers

Hoist & Winch helps bridge the lifting expertise gap

Reinforcing the piers that support a major UK rail viaduct spanning a river estuary is no easy task, which is exactly why the specialist marine subcontractor appointed to undertake this project approached Hoist & Winch Ltd for the optimal lifting solution.

The brief provided to Hoist & Winch was for the supply of a turnkey lifting solution comprising two sets of four hoist units suitable for a marine environment. These hoists were to be suspended from temporary scaffold structures fixed to two separate motorised floating pontoons. As part of an innovative approach to a complex challenge, the hoist-mounted pontoons would serve to locate special horseshoe-shaped reinforcing concrete collars either side of one of the bridge piers at high tide, prior to joining the collar halves together above the water with connection pins. Finally, the collar halves would require lowering to the river estuary bed for permanent fixing to the piers with concrete at low tide, thus providing the necessary reinforcement.

To establish the optimal package of hire equipment, as well as site installation, load testing and additional technical support services, Hoist & Winch consulted extensively with both the motorised pontoon designers and installation personnel responsible for lowering the special concrete collars into position.

After reviewing all the information from project stakeholders, Hoist & Winch subsequently proposed eight JDN top-hook suspension air-powered hoist. Each of these 3t swl (safe working load) hoists featured its own heavy-duty steel lubricator coupled with appropriately sized air supply hoses. The two sets of four hoists units would be operated from their own individually connected, heavy-duty (brass) two-button pendant control.

In order to monitor the load applied to each hoist unit and assist with delivering a balanced collar lowering procedure, Hoist & Winch also provided eight telemetry load cells of bow-shackle design. These load cells served to connect each hoist unit to its local scaffold anchor support position, transmitting individual hoist load data via radio signal to a central laptop display. Armed with this data, the appointed person directing lifting operations could instruct each hoist operator accordingly to ensure the load was evenly distributed between each set of four hoists and that each collar was lowered into position while remaining level.

Prior to commencing the process of installing and lowering the concrete collars, Hoist & Winch carried out the installation of the eight air-powered hoist units. This work included pre-use inspection, static load/deflection testing, and LOLER (Lifting Operations and Lifting Equipment Regulations) certification of the temporary scaffold structure and complete hoisting system.

Hoist & Winch also provided technical consultancy as part of the overall package, delivering guidance on important project areas such as lifting equipment legislation, lifting operation planning and management, and specification and procurement of the portable diesel-powered air compressors to power the hoist units. In addition, the company delivered full handover training for operators.

Both the specialist marine subcontractor and end client were extremely pleased with the final outcome, which saw the successful installation of two sets of trial pier-reinforcing concrete collars to the viaduct as part of a safe and controlled process.

“This specialist project demanded the application of our expertise and experience to ensure a successful conclusion in line with the appropriate safety standards and high performance levels demanded by our client,” says Andy Allen, Director of Hoist & Winch Ltd. “We worked closely with project stakeholders to ensure the delivery of a robustly engineered lifting solution with precision control. Quality solutions and service from Hoist & Winch once again led to a project that concluded with the highest levels of customer satisfaction.”

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web: www.hoistandwinch.co.uk

Hoist & Winch performance reaches new heights in roof replacement project

When a landmark building in Nottingham required the replacement of its fabric tensile roof covering, the subcontractor tasked with this critical work turned to the expertise of Hoist & Winch Ltd for the roof lowering and lifting solution. The eye-catching building, a former HMRC complex similar in design to London’s O2 Arena, is today part of Nottingham University’s Castle Meadow Campus.

The leaking tensile roof covering had reached the end of its 30-year lifespan and required replacement. To ensure the optimal solution to this technically complex challenge, the specialist subcontract responsible for the job approached Hoist & Winch. The objective for Hoist & Winch was to specify and supply a complete hoisting solution that would enable safe, even lowering of the original fabric roof to ground level and raising of the replacement fabric roof to its final installation height.

Following a number of site meetings and consultations with both designers and roof installation personnel, Hoist & Winch was able to propose a complete package of equipment and technical support.

At the centre of the proposal were 12 Yale/CM Lodestar electric chain hoists. These 2t swl (safe working load), 110V top-hook suspension hoists were coupled with correctly sized 30m long power feed/control cables. The idea was to operate the hoists simultaneously in sets of four while suspended from the customer’s specially designed lifting beams. Hoist & Winch also provided three separate single free-standing control stations of bespoke design to manage hoist unit motion, either individually or in sets of four, during lowering of the original fabric roof and lifting of its replacement.

Another aspect of the project saw Hoist & Winch supply a combination of 15t and 6.3t swl William Hackett lever hoists to assist with de-tensioning the original fabric roof prior to lowering operations and re-tensioning the new fabric once lifted into its final position.

As always, technical consultancy proved a core element of the overall package from Hoist & Winch. The company’s highly professional approach ensured the specialist roofing subcontractor received guidance on project-critical factors such as lifting equipment legislation, lifting operation planning and management, overall design and sizing of two bespoke portable electrical transformers, electronic load cell selection, selecting loose lifting tackle, and site examination and testing procedures prior to the commencement of lifting operations.

“The outcome was the safe and successful removal of the original fabric roof and the installation of its replacement as part of a finely controlled, smooth process,” reports Hoist & Winch Director Andy Allen. “The customer was delighted with the professionalism of our expert team and the solutions we proposed. Taking projects like this from concept to fruition is where we excel, ensuring our customers meet all of their objectives in a safe, competent and timely manner.”

Such was the impression made on the specialist roofing subcontractor that it subsequently engaged Hoist & Winch in further work to adapt the already acquired lifting system and used the knowledge gained from the Nottingham project to bid successfully for another multi-point lifting project in Copenhagen.

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

Construction project presses home the advantage of using Hoist & Winch

To ensure the safe, effective and efficient transfer of plant equipment into the basement energy room of a new residential tower block in London, a major construction project leveraged the advantages of appointing Hoist & Winch Ltd as its supplier of turnkey lifting equipment. Tasked with meeting the requirements of a technically challenging brief, Hoist & Winch demonstrated why it has become the nation’s go-to solution provider of high-quality lifting systems.

Many new tower block development projects face a common challenge: how to install large, heavy pieces of equipment into the building’s energy centre, typically located in the basement. Specifying the optimal hoists is paramount to project success. Fortunately, the subcontractor supplying and installing the energy room’s plant for this particular project knew where to turn for a turnkey lifting solution: Hoist & Winch Ltd.

Hoist & Winch has extensive experience in all kinds of construction and industrial lifting applications. The company offers sales, installation, service, inspection, repair and hire services, with a special emphasis on project work. Supplying the optimal solution, with safety as the number one priority, is always the objective.

During the design phase, after formal tender and contract award, Hoist & Winch set about identifying the optimal solution by carefully assessing the specific lifting requirements. The project required the installation of hoists on both the upper and lower ground floor levels to ensure the successful lifting and transfer of large energy plant. It was clear from the outset that the solution would need to overcome the issue of very tight headroom clearances due to the size of the equipment.

                                                                                                                                                            

After thoroughly considering all aspects of the project, Hoist & Winch Ltd was able to put forward its proposal, recommending two William Hacket low-headroom manual hoists, both with a hand-geared trolley. Offering a safe working load (SWL) of 2.5t each, the hoists provide 8m of lifting height and run on beam lengths of 8.5m and 7.0m.

Hoist & Winch duly submitted its design proposal, including drawings and structural calculations, for approval by engineers at the main contractor. Following approval, the company commenced manufacture before delivery to site.

During the installation phase, Hoist & Winch tested the installation anchor points to 1t before raising each beam into position using hand chain blocks. Elevating the beams to full height and clamping them hard against the concrete ceiling ready for drilling required the use of special lifting rigs. Once in position, the company proceeded with drilling operations and resin anchor installation for all ceiling anchor points after meticulously cleaning each hole with a special heavy-duty internal brush and suction pump. Following the specified resin curing time, Hoist & Winch tightened each anchor bolt to the required torque levels.

LOLER (Lifting Operations and Lifting Equipment Regulations) inspection of the lifting beams and manual chain hoist units was the final operation. This activity included dynamic load testing of both beam lengths with a 2.5t skid-mounted test load followed by 125% static proof load test in accordance with BS 2853 2011. As a point of note, following customer handover, the hoists were to remain in place for use by the on-site maintenance team.

“We provided the client with a comprehensive project records and documentation package upon completion of works, which is standard practice,” says Hoist & Winch Director Andy Allen. “We then went through the handover process to ensure total peace of mind for our client. At Hoist & Winch, our focus is on ensuring customers benefit from our exceptionally knowledgeable team who never fail to deliver on their promise of providing a detailed and proficient approach to every project.”

                                                                                                                                                         

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

Embracing the new era of connected safety

When your business involves sending hundreds of workers out to disconnected sites where they could be exposed to dangerous gases, safety should be a top priority. But how can real-time insights and actionable data help enable you to offer your workforce enhanced protection? This was the challenge facing Cappagh Browne Utilities Limited, a company specialising in repairing and maintaining wastewater networks across the southeast of England. Learn more about their experience.

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As managing director of Cappagh Browne, Jeff Birtwhistle plays a key role in helping to keep the sewers of south-east England flowing. With over 30 years’ experience in heavy civil construction, nuclear energy, and utilities, he’s always looking for innovative solutions to help the company improve the service it offers customers – and protect its workforce. So when we introduced our latest generation connected gas connector, the ALTAIR io™ 4 Connected Gas Detector, Jeff was keen for Cappagh Browne to be able to reap the benefits.

“When it comes to innovation and new technology, MSA Safety is one of our key and invaluable partners,” he says.

The gas detector that is redefining safety management

Cappagh Browne was already using a previous generation connected gas detector from MSA Safety that provided certain data for remote monitoring to help protect workers and respond to emergencies.  After experiencing those benefits, he wanted to enhance them even further with real-time data. The ALTAIR io 4 Connected Gas Detector does this, helping to give Cappagh Browne the chance to leverage new MSA Safety technology, improve overall business efficiency and response times, and significantly improve safety for workers.

Offering immediate, on-site connectivity

The power of the  ALTAIR io 4 Connected Gas Detector lies in its combination of built-in cutting-edge, CAT-M LTE cellular connectivity and integration with the MSA Grid. Part of MSA Safety’s Connected Work Platform, the ALTAIR io4 Connected Gas Detector can be deployed in seconds, right out of the box. What’s more, no IT is required for updates because they are delivered securely from our cloud to your fleet. When the device is in its dock, it knows when it needs a bump test or calibration to be compliant and immediately starts to run the relevant test. And with industry-leading XCELL® sensors it can stand up to tough use in challenging conditions, resistance to extreme temperatures, the ability to withstand a 25-foot drop and a dust and waterproof IP68 rating.

Real-time insights

Matt Reid, Head of Fleet for Cappagh Browne, says they are already experiencing the benefits of upgrading to the ALTAIR io 4 Connected Gas Detector. “We have over 350 employees working across various remote sites in potentially hazardous environments. So real-time safety monitoring is important,” he explains. “Now, with the ALTAIR io 4, we’re able to use real-time data to establish who to use on a particular job because we can see what exposure they’ve had over the last week.”

“We can send one person out to a job and then, if they need help, we can send another person out with an ID tag to ‘fob on’ to the same device. We can then track both people safely within the seven-day period to make sure they don’t exceed their exposure limit.”

Keeping workers safe throughout the day

Managing Director Jeff Birtwhistle adds that it’s the ability to get immediate feedback when a worker’s exposure limit to dangerous gases has been reached that is taking the company’s safety management to new levels. “Being able to intervene on a worker’s behalf and pull them out of a job to protect them is fantastic. It means we can keep our most valuable asset –our people – safe,” he says.

Improving compliance

The real-time data and actionable insights offered by the ALTAIR io 4 Connected Gas Detector are also helping to simplify regulatory compliance for Cappagh Browne and enabling supervisors to identify behaviors that don’t meet safety standards, which can help make workers more accountable.

Since introducing the solution, the company has experienced zero safety alarms. However, as Matt Reid explains, a worker was able to use the inbuilt alarm to call for help in an unusual situation.

“We had an instance where a guy became physically locked out of his vehicle and didn’t have his phone on him. He pushed the alarm button to call for help and we were able to get a second set of keys over to him to unlock the vehicle and get him on the road again.”

The partnership with MSA Safety continues

Both Jeff and Matt know that at some point in the future they will inevitably be looking for new safety enhancements that they cannot envisage right now. But they are confident that when that time comes, MSA Safety will be there, just as it has been for real-time gas detection monitoring. For now, they are enjoying the enhanced safety that the ALTAIR io 4 Connected Gas Detector offers their workforce.

Fleet manager Matt Reid sums up the benefits. “Using ALTAIR io 4 means we can send our employees home safely to their families every night and that Cappagh Browne can see them again every morning when they turn up for another day’s work.”

Keen to see what this technology can do for safety management at your business too? Watch our case study video and find out more about how the ALTAIR io 4 Connected Gas Detector is redefining safety.

 

Hoist & Winch is pillar of support in overhead crane project

The design and installation by Hoist & Winch Ltd of replacement end carriages for two overhead cranes reached its conclusion recently with the end user expressing complete satisfaction in the outcome. Previously, the 2-ton swl (safe working load) manual overhead cranes were suffering from potentially dangerous crabbing problems due to the original design of the end carriages. Hoist & Winch thus had a responsibility to work expediently and professionally, with the aim of bringing this concerning issue to a safe resolution.

Alongside the supply, installation, hire and load testing of hoist units/cranes for all types of industries, Hoist & Winch also offers lifting equipment refurbishment and rectification services. With each project of this type presenting its own set of challenges, the company comes to the fore in tackling work that competitors often prefer to avoid.

For this project, the relatively high-temperature working conditions and access requirements were a factor due to the basement location of the manual cranes in a large, ageing building in central London. The cranes work over two large gas-fired piston engines that provide heat to neighbouring buildings.

The core objective was to design and install replacement end carriages for the cranes that in the first instance would eliminate the potentially dangerous crabbing issues. Due to this problem, the cranes had not performed correctly since initial installation.

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Crabbing occurred because the original end carriage wheelbase was insufficient for the crane span, exacerbated by insufficient tread depth on the crane wheels. During long travel motion, the end carriage wheels would try and ride up (crab) on to the crane rails, a situation that can potentially lead to crane derailment.

With a solution required urgently, Hoist & Winch performed a detailed site dimensional survey to gather important design information and check the alignment of the existing crane rails. The company then set about designing replacement end carriages with a longer wheelbase and new crane wheels featuring deeper tread. Side-acting crane rail guide rollers at each extent of the end carriages were a further important part of the new design.

Working closely with the customer’s on-site scaffold team, Hoist & Winch carried out a comprehensive installation survey. For the rectification work, the scaffolders agreed to build a temporary tube and board scaffold below each crane, providing both general access and jacking positions to raise and lower the cranes when replacing the end carriages.

Hoist & Winch submitted a Risk Assessment Method Statement (RAMS) for approval by the customer. The RAMS detailed the installation procedure, the required equipment, and the hazards and risks associated with the various tasks and how appropriate actions would mitigate accordingly.

Following a five-week period to manufacture the replacement end carriages, installation took place over four days for both cranes. The work included dynamic load and 125% proof load testing with a certified roller test load for each crane. A series of lifting beams helped to move the test load into the basement area via the use of temporary manual hoist units.

Hoist & Winch issued a Thorough Examination report in accordance with LOLER (Lifting Operations and Lifting Equipment) regulations.

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“The new replacement end carriages served to eliminate the crabbing issues exhibited by the original crane design,” confirms Hoist & Winch Director Andy Allen. “Our customer was very satisfied as they could carry out essential maintenance work on the gas-fired piston engines that was previously delayed. The successful conclusion of this task is yet another example of how Hoist & Winch works with its customers in a professional way to overcome challenging issues and bring genuine added-value to lifting projects.”

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

 

Polymeric Leading Edge Protection Extends Lifespan of 42 Wind Turbine Blades

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Figure 1. Leading edge protection of wind turbine blade using polymeric technology

                                                                                                                                                                                               
In order to achieve net-zero by 2050, according to a 2023 Report from the world-leading authority on climate science, Climate Action Tracker: ‘wind and solar sources in electricity generation will need to reach 57 - 78 percent by 2030, and 79 - 96 percent by 2050.’ In 2022, this figure sat at 12 percent. Needless to say, a colossal scale-up of these industries is anticipated over the upcoming decades.

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Figure 2. Historical progress toward 2030, 2040 and 2050 targets for share of wind and solar sources in electricity generation (Source: State of Climate Action 2023)

Polymeric Technology Supports Transition to 79 – 96% Renewable Energy by 2050

Given the important role wind power plays in the transition to net zero, it is absolutely critical that windfarms are maintained to an excellent standard. Otherwise, damaged wind power assets may needlessly be decommissioned and replaced; the process of which comes with a hefty carbon footprint as well as considerable financial expenditure.

As such, asset owners are investing in a simple yet extremely beneficial (both from a cost and environmental perspective) solution to extend the lifespan of wind turbines. This solution involves the use of polymeric repair composites and high-performance protective coatings to repair and protect key assets in the wind industry. This includes: turbine blades, nacelles and generating components, turbine bases, towers, transformers, amongst other assets.

The use of this technology is based on a circular economic business model: repairing damaged assets rather than replacing them. In turn, not only does this mitigate the carbon footprint incurred during the replacement process, but it is also enables the asset owner to make significant financial savings as well.

Case Study: 42 Wind Turbine Blades Repaired and Protected

At an onshore Windfarm in Denmark, 42 wind turbine blades were exhibiting signs of severe erosion on the leading edges. Previously, the Customer had used pre-formed shells that were bonded onto the substrate to provide leading edge protection. However, this process proved to be extremely time-consuming and expensive. Therefore, the Customer was seeking an alternative solution which would be financially viable and also ensure optimal operation for many years to come.

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Figure 3. Damaged wind turbine leading edge


Specification of Polymeric Leading Edge Protection System

Based on test results, the ease of application as well as the high-quality finish that can be achieved, the Customer decided to repair and protect the leading edges with a combination of Belzona 5711 and Belzona 5721.

The thixotropic paste, Belzona 5711 is specially designed to be applied in conjunction with the Belzona 5721 protective coating. This solvent-free LEP system is formulated for the in-situ repair and rebuilding of leading edge erosion and impact damage on wind turbine blades.

Simple Application Method

Commenting on the application process, Morten Sivertsen, General Manager at AESSEAL Danmark A/S said: “Surface preparation was carried out on each of the 42 blades, followed by the direct application of 90 kg (198.4 lbs) of Belzona 5711 from self-mixing cartridges onto the blade. The repair area was then contoured using a piece of Belzona mixing board. Once cured, a visual inspection was conducted to ensure the application’s readiness for overcoating with 144 kg (317.5 lbs) of Belzona 5721. Using a short-bristled brush, this system was then applied to the leading edge and left to cure for 30 – 60 minutes. With three rope access technicians carrying out the applications, on average, six – nine turbine blades were completed each day.”

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Figure 5. Morten Sivertsen, General Manager at AESSEAL Danmark A/S

 

In-Situ Repair Ensured Minimum Downtime Was Incurred

As the polymeric systems were applied in situ without the need for specialist tools or equipment, this ensured that a fast and seamless application was carried out. Thus, this enabled the Customer to make considerable financial savings as it mitigated the profit loss that can be incurred through lengthy periods of downtime.

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 Figure 6. Leading edge repaired and protected with Belzona 5711 and Belzona 5721

 

Safeguarding Key Wind Power Assets for the Long Term  

 

The scaling up of the wind power industry is absolutely critical in order to support the transition to renewable energy, in keeping with the net zero by 2050 pathway. By safeguarding key assets within this industry through the use of polymeric technology, asset owners can successfully bypass the environmental and financial costs associated with asset replacement. Therefore, it could be argued that polymeric technology plays an intrinsic role in supporting this energy transition. 

 

About AESSEAL DANMARK A/S:


AESSEAL DANMARK A/S is a subsidiary owned by AESSEAL Plc and is the authorised Belzona Distributor for the Denmark territory. Established in 1999, AESSEAL DANMARK A/S provide industrial repair composites and protective coatings to a variety of industries including petrochemical, mining, power, sugar, pulp and paper, amongst others.  

Please click on the following link for more information about AESSEAL DANMARK A/S.

Electric hoist leaves large distillery in high spirits

The world’s largest producer of spirits is now benefiting from a turnkey package of three Italkrane ATEX-rated electric chain hoists supplied by Hoist & Winch Ltd. Operational within a new extension of the Scotland-based distillery, the 2-ton swl (safe working load) hoists raise and lower sealed vessel lids and baskets containing raw materials used in the production of gin.

Among the challenges of this demanding project was a restriction in the overall height of the new building due to local planning laws. In turn, only limited headroom is available for lifting operations over the vessels. Critical for the application, therefore, was the specification by Hoist & Winch of Italkrane YY series electric chain hoists featuring a low-headroom design. The ATEX specification of the hoists is necessary due to the vapours and fumes produced in the manufacture of alcohol-based products.

Italkrane YY series electric chain hoists feature an Ex d electrical enclosure design to contain any explosions and stop flames, sparks and hot gases from escaping. Full anti-spark features are in place for all components subject to sliding friction, including the brass trolley wheels. Also present is a non-sparking load hook, brass anti-tip device and polycarbonate pendant control ensuring explosion protection up to Zone 1 II B T4 classification.

The power supply to each hoist unit is via a festoon cable track system complete with sliding trolleys and support arms clipped to the top flange of the hoist runway beam. Each hoist unit also features an Italkrane heavy-duty geared top/bottom limit switch and friction-type slipping clutch overload protection device.

                                                                                                                                                            

“Although we provide a full spectrum of lifting equipment services, Hoist & Winch is particularly at home supplying equipment for demanding industries, including the distillery sector,” explains Hoist & Winch Director Andy Allen. “We have extensive knowledge of this industry, where our quality of service and flexible approach ensure the highest levels of customer satisfaction.”

Due to the critical nature of the project and the risk of explosion throughout the high-risk site, it was clear that very stringent planning and close monitoring of working practices would be necessary at all times. In addition, the site work was subject to Construction Design and Management (CDM) Regulations, supported by a requirement for all site engineers to hold a valid CCNSG Safety Passport/CSCS competency certification.

Installation took place over seven days, with a Hoist & Winch CompEX-certified electrical installation engineer completing all connection work. The load testing of each hoist unit and complete runway beam took place using a dynamic test load of 2t + 125% proof load. Additional functional testing using the vessel lids and raw material baskets proved system functionality in line with customer requirements.

Following the issue of a LOLER (Lifting Operations and Lifting Equipment Regulations) Thorough Examination Report for all installation work, Hoist & Winch provided on-site training for the distillery’s operating personnel.

Although providing the optimal solution for this large distillery, Italkrane ATEX-rated electric chain hoists are also suitable for many other applications requiring safe lifting operations in explosion risk environments. In addition, Hoist & Winch can offer ATEX wire rope hoists for longer lifting tasks, heavier loads up to 50t swl and higher duty applications.

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

Heavily Corroded 872 Metre Oil Pipeline Restored with Composite Wrap

An underground oil pipeline at a Refinery in Spain was suffering from severe corrosion. If left unchecked, the pipeline, 872 metres (2860.8 ft) in length, would have incurred severe metal loss. As a result, disastrous consequences, both financially and also from an environmental perspective, would have ensued.


Figure 1. Corroded pipeline restored with composite wrap

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Solution Sought to Mitigate Cost and Carbon Footprint of Pipeline Replacement   

A prompt repair was required for the carbon steel pipeline, 55.9 cm (22 inches) in diameter, in order to mitigate any further corrosion damage being incurred. In fact, if left unchecked, this would have caused the substrate to completely corrode through and, therefore, serious environmental issues would have ensued.  

A potential solution would have been to completely replace the pipeline. However, considering its mammoth length, this process would have required considerable financial expenditure and, furthermore, would incur a hefty carbon footprint.

For every ton of steel that is produced, 1.85 tons of CO₂ - nearly double the amount - is released back into the atmosphere (Carbon Clean). In addition to this, the process of removing and disposing of the damaged pipeline further ratchets up the carbon footprint of this process.

As well as the environmental impact of replacing the corroded pipeline, this process would also require a considerable period of downtime which would lead to further profit-loss. The combination of these factors, costly in both a financial and environmental sense, led the Customer to seek out an alternative solution to replacing the steel pipeline.  

Expensive Replacement Process Bypassed with Composite Wrap

The Customer decided to repair and protect the pipeline with a combination of polymeric technology in order to bypass the drawbacks associated with replacing the pipeline.

The following systems were specified and applied following an inspection from Elena Expósito Fernández, AMPP (NACE) Certified Coating Inspector Level 2 and Technical-Commercial Delegate at authorised Belzona Distributorship Rodator Composites:  

“The 2-part epoxy paste, Belzona 1111 (Super Metal), was specified to fill in any gaps in the weld seams to ensure the pipeline had a smooth profile. For heavily corroded areas, plate bonding was required using steel plates which were 50 cm x 60 cm (19.9 in x 23.6 in) in size, with a thickness of 5 mm (0.2 in). These were bonded into place using the epoxy structural adhesive, Belzona 7311. To reinforce the pipeline, the composite wrap, Belzona SuperWrap II, was specified. Finally, the anti-corrosion coating, Belzona 5811 (Immersion Grade), was chosen to provide long-term corrosion protection.”   




Figure 2. Elena Expósito Fernández, Technical-Commercial Delegate at Rodator Composites

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Figure 3. Application of composite wrap, Belzona SuperWrap II, to the steel pipeline

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Figure 4. Anti-corrosion coating, Belzona 5811 (Immersion Grade), applied to pipeline

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Polymeric Technology Supports Decarbonisation of Oil and Gas Industry    

The Customer was able to successfully bypass the drawbacks associated with complete pipeline replacement by instead, opting to repair and protect the pipeline with a combination of polymeric technology. As well as making huge financial savings, this solution enabled the Customer to also minimise its environmental impact as well.

As the oil and gas industry continues to decarbonise, this latter point is particularly paramount. Polymeric technology is an extremely viable way in which oil and gas asset managers can make great strides in mitigating the carbon footprint of their facilities. An increased uptake in the use of cold-applied repair composites and protective coatings would help to accelerate the decarbonisation of this industry.

For more information, visit: www.belzona.com

Ensuring Safety in Hazardous Environments: A Case Study on ATEX Safety Showers

In industries where flammable gases, vapours, and dust are present, ensuring the safety of employees is of paramount importance. The European Union's ATEX Directive 2014/34/EU, aim to regulate equipment used in potentially explosive atmospheres, requiring companies to implement safety measures that mitigate the risk of ignition and protect personnel. This blog examines a company's implementation of ATEX safety showers to enhance workplace safety and meet regulatory compliance.

All chemical manufacturing facilities that handle or specialise in the production of volatile chemicals, it is imperative to adhere to ATEX regulations to protect employees from potential hazards. One of the key aspects of ATEX compliance is the provision of safety equipment, including safety showers and eye wash stations, to ensure the safety of workers in the event of chemical spills or exposure.

The Challenge and Solution

Compliance with ATEX Regulations: The company needs to comply with ATEX Directive 2014/34/EU, which required the implementation of safety measures to prevent explosions in areas with potentially explosive atmospheres. This includes providing ATEX-compliant safety showers.

Employee Safety: The safety of employees working with volatile chemicals is a top priority. You need to ensure rapid and effective decontamination in case of chemical exposure.

Equipment Selection: Choosing the right ATEX-compliant safety showers is essential.  You must evaluate the specific requirements of your facility, including location, potential hazard levels, and the number of showers needed.

 This is something Aqua Safety Showers can help with.  We manufacture a full range of safety showers designed to meet the specific needs of sites and provide optimal protection.

Get peace of mind knowing that safety showers from Aqua Safety Showers will be manufactured from corrosion resistant materials and come with a two-year warranty, further promoting a safety-conscious workplace culture.

www.aqua-safety.com

 

Belzona Repairs Propeller Shaft on Ship Carrying Olympic Torch

On May 8th, 2024, the historic Ship the Belem navigated into the bustling port city of Marseille, marking the arrival of the Olympic torch in France. Over 150,000 spectators gathered to witness as the Ship sailed into the bay, accompanied by over a thousand boats. Last year, Alliatech, one of Belzona’s French distributors, was involved in the restoration of this historical Ship.

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The Belem arriving in Marseilles with the Olympic flame             Credit: Benoit Tessier / Reuters

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Photograph of spectators gathered in Marseilles, taken from the Belem as it arrived. Credit: Nicolas Tucat / AFP

The History of the Belem:

Considered to be the last great French merchant Ship, the Belem is an impressive three-mast Vessel reaching 34 metres (112 ft) tall and 58 metres (90 ft) long. As well as possessing an impressive 22 sails with a huge surface area of 1,200 m2  (1435 yd 2), it has two 575 horsepower diesel engines, blending tradition with modernity. Interestingly, carrying the Olympic flame has not been the first time the Belem has had a fire on board. The Ship caught ablaze during its maiden voyage in 1896, the same year the Olympic games were revived, on its way to Belem, a Brazilian port city and the Ship's namesake, but it was repaired and able to continue its visit.

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The Belem made her maiden voyage in 1896, the same year as the first Olympic games

The Belem’s Olympic Voyage:

On Saturday 27th April, once the Olympic flame was lit in Athens, it began its 2000 km (1242 mile) journey from the port of Piraeus to Marseille. The Olympic flame was watched 24 hours a day to ensure it stayed lit and twelve days later, it reached the French coast. A celebratory event anticipating the arrival of the Ship in France featured 800 luminous drones forming a torch in the air followed by a pyrotechnic show. As the Vessel docked, an Air Force flyover featured planes drawing the Olympic rings and the colours of the French flag as over 150,000 lined the streets of Marseilles.

Case Study: Propellor Shaft Suffering from Heavy Corrosion

The propellor shaft on this 19th Century Naval Ship was severely damaged, suffering from heavy corrosion and pitting. The Customer was keen to preserve the shaft, given its historical significance; replacing it would be extremely costly, and they were reluctant to lose a piece of the original Vessel. It was vital that the chosen solution could reconstruct the damaged areas of the shaft and protect it from future seawater corrosion.

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The propeller shaft showed heavy wear due to seawater corrosion

Alliatech, a Belzona-authorised distributor with over 40 years of experience, was chosen to carry out the repair. The application took place whilst the Belem was in dry dock in the Saint-Nazaire Shipyards as part of the Ship's extensive restorations. After grit-blasting and salt-washing the surface, the damaged propeller shaft needed to be reconstructed back to its original profile. Belzona 1111 (Super Metal), a repair composite for metal repair and resurfacing, was chosen for the rebuilding.

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Propellor shaft rebuilt using Belzona 1111 (Super Metal) after first coat of  Belzona 5821

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Final application with the second coat of Belzona 5821

Two coats of Belzona 5821 were then applied to protect the shaft from future seawater corrosion. This product was specially designed to offer long-term protection from erosion and corrosion under immersion, thus providing excellent defence against the effects of salt water.

The application of these two Belzona products allowed the original 127-year-old shaft to be retained, avoiding the costly replacement, and maintaining a piece of history.

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