What will you do if you notice there is corrosion on your flanges? Some maybe suggest replacing it with a new one but money is still the big issue here. What if we have a better solution to help you save costs and downtime for the long term?

3 ways we can help you to save on cost and downtime.

1. Flange Face Forming.

The corrosive action of chemicals, crevice corrosion, bimetallic corrosion and high-pressure steam can result in the deterioration and subsequent leakage of flanges. Proven for over 10 years, the Belzona flange face-forming technology eliminates the need for conventional cut and weld methods involving hot work. It allows for a simple application in emergency situations, especially in areas with limited access such as on offshore platforms. 

Therefore, the Belzona Flange Face Forming kit is a unique repair kit developed to aid flange protection by combating the common problems with mating surfaces of flanged joints, such as heat distortion, corrosion, and erosion. In conjunction with Belzona 2-part epoxy repair composites such as Belzona 1111 (Super Metal), this flange repair kit provides a complete package solution that is cost-effective and simple to implement.  When used with a Belzona epoxy repair composite such as Belzona 1111 (Super Metal), this system will combat the common problems with mating surfaces such as heat distortion, corrosion and erosion.

Key Benefits:

  • Simple to use

Simple to use as all the necessary accessories are in one kit

  • Re-usable

Each flange face former can be used hundreds of times and if a former gets damaged it can be easily replaced as a spare part.

  •  No hot work

The Flange Face Forming Kit is used in conjunction with Belzona’s cold repair technology materials, avoiding hot work problems involved in conventional cut and weld methods.

  • Lightweight

The light weight of the Flange Face Forming Kit allows easy transportation for emergency situations and areas with limited access.

  • Minimised downtime

The Flange Face Forming Kit eliminates the need for replacement parts significantly reducing downtime. Emergency repairs can be completed in place with minimal disruption to daily operations.

2. Flange protection with Belzona’s encapsulating membrane

A 2-part hybrid polymer coating for the encapsulation of any shape, size or configuration of flanged joint or other equipment. Designed to exclude moisture and prevent crevice, galvanic and atmospheric corrosion, Belzona 3412 is a tough, isocyanate-free, flexible topcoat which does not require heat or specialist tools for its application.

Belzona 3412 can be simply applied by brush or spray to new or deteriorated equipment to provide outstanding long-term corrosion protection. When used in combination with the release agent/corrosion inhibitor, Belzona 8411, the coating can be easily cut, peeled back and resealed to allow inspection of fastenings.

Additionally, Belzona 3412 can be used in conjunction with the Belzona Spray Gun. This facilitates a fast and efficient application whilst providing the same outstanding coverage and protection as a brush application.

Key Benefits:

  • Simple application

No specialist tools are required—quick brush or spray application to manually prepared surfaces. It also works in conjunction with the Belzona spray gun.

  • Outstanding corrosion protection

Belzona 3412 possesses high adhesion, durability and flexibility, preventing moisture ingress.

  • Peel and reseal feature

The encapsulating membrane can be cut and peeled for inspection during maintenance and then resealed to reinstate protection.

  • Safe to use

Belzona 3412 is a moisture-cured, isocyanate-free system

3. Flange Rebuild with Belzona 1111

The above photos are the model of worn flanges that we did in our lab. We purposely damaged the flange and will rebuild it into its original form using Belzona 1111.

Belzona 1111 (Super Metal) is a cold-curing 100% solids epoxy composite reinforced with silicon steel alloy.

This material can be used for various applications including bonding, shimming, forming, rebuilding, wrapping, patching, sealing and filling.

It will not shrink while curing in service, allowing for exact dimensions and geometry to be achieved. Belzona 1111 ensures lasting in-service performance, accounting for temperature and pressure fluctuations, loading and stresses, impact and abrasion.

Five-year shelf life makes Belzona 1111 an invaluable stock item for many professionals.

The damaged flange has been repaired to its original shape and geometry using the Belzona 1111 (Super Metal).

Key Benefits:

  • Multi-purpose

Can be used for bonding, irregular shimming, forming, rebuilding, wrapping and patching.

  • Durable

High compressive strength, impact and abrasion resistance.

  • High precision

Moulds to precise contours and can be machined with conventional tools.


  • Simple application

Easy to mix and apply with no specialist tools.

  • Versatile

Adheres well to almost any substrate and can be applied in thick sections in one operation.

  • 100% Solids
No shrinkage, expansion or contraction during cure.


Oil & Gas

Belzona’s wide range of epoxy-based metal repair composites, high-temperature coatings and linings have been used in the Oil and Gas industry since the late 1970s.

Our materials are specifically designed to provide outstanding erosion and corrosion protection and chemical resistance for equipment operating offshore and onshore at various temperatures and pressures. Belzona offers cost-effective solutions, which reduce downtime and labour costs while eliminating the need for equipment replacement.