Corrosion is one of the most common challenges faced by pump housing, eventually requiring repair. Or if the problem has become so bad, system replacement.
Over time, exposure to moisture, chemicals and abrasive materials can cause the housing of pumps to degrade. This leads to inefficiencies, leaks and even catastrophic failure.
Fortunately, there are effective solutions for the repair and restoration of corroded pump housing.
Understanding the problem: Corrosion in pump housings
Pump housings are susceptible to corrosion due to their constant exposure to harsh environments. Corrosion can result from several factors, including:
- Moisture and humidity: Water can react with metal surfaces, causing rust and corrosion.
- Chemical exposure: Certain chemicals, such as acids and alkalis, can accelerate the breakdown of the metal.
- Abrasion: The movement of abrasive particles through the pump can wear down the housing, exposing it to further damage from moisture or chemicals.
As corrosion progresses, it creates pits and holes in the pump housing. This surface damage compromises the pump’s efficiency and can potentially lead to leaks.
If left untreated, corrosion and pitting will cause the pump to fail entirely – meaning costly repairs and potentially significant system downtime.
Pump housing repair and protection using epoxy wear compound
An epoxy wear compound like WearShield Impact Resistant Epoxy Paste provides an ideal solution for the repair and protection of corroded pump housing.
WearShield is a two-part paste heavily filled with alumina beads. These beads give the cured material ultimate surface hardness and resistance to corrosion, abrasion, impact and chemical attack.
When applied to pump housing, WearShield forms a protective layer which not only restores the integrity but also helps extend the lifespan of the equipment.
WearShield is ideal for use in a wide range of industrial applications beyond pump housing, including valves, ash handling systems and other machinery components that are exposed to harsh environments.
The paste is easy to mix and apply, requiring no special tools or expertise. This makes it perfect for on-site repairs and minimising downtime.
How to repair corroded pump housing with WearShield
Before you begin, make sure the pump is turned off, disconnected from power sources and properly isolated.
Depending on the size and design of the pump, you may want to drain the fluid from the system to avoid contamination.
1) Surface preparation
Thoroughly inspect the corroded area on the pump housing before repair. If the corrosion is significant, you may need to remove any loose material.
This can be done using a wire brush or sandpaper. Clean the area thoroughly to remove any dirt, grease, oil or moisture. You can use a clean rag and solvent to wipe the area down.
2) Mix the epoxy wear compound
WearShield comes in two parts: a resin and a hardener. The mix ratio and time will be specified with the product instructions.
Ensure you mix the components thoroughly until you achieve a uniform consistency. The white and black parts should have sufficiently mixed to turn into a grey, streak free paste.
Once mixed, the epoxy will begin to cure. Only mix enough for your immediate use, otherwise you risk it setting before completing the application.
3) Apply the epoxy wear compound
Using a putty knife or spatula, apply the mixed WearShield to the corroded area. Smooth it over the surface, ensuring it completely covers the damaged section.
If the corrosion has caused deep pits or holes, fill them with additional layers of paste. Ensure each layer is smooth and level before applying the next.
For larger areas, you can apply a thicker coat for more robust protection. The manufacturer state ultimate protection is offered by building WearShield up to be 6mm thick.
4) Shape and smooth the surface
If necessary, use a putty knife or other tool to smooth and shape the epoxy paste as it cures. You can also use masking tape to create clean lines or edges around the repair area if the corrosion is near a boundary or joint.
To create a smooth surface, apply a small amount of isopropyl alcohol or acetone to a paste spreader or putty knife. Run the spreader of knife over the WearShield surface.
5) Allow the epoxy to cure
Once applied, allow WearShield to cure undisturbed according to the manufacturer instructions and timings.
Cure time is dependent on ambient temperature and the thickness of the repair. If possible, leave the pump housing for 24 hours to allow WearShield to reach maximum properties.
6)Final inspection and testing
After the epoxy has fully cured, inspect the repair for any inconsistencies or areas that may need additional attention.
Once you are satisfied with the repair, reassemble the pump and test it under normal operating conditions.
Improve pump performance with WearShield
Corrosion in pump housings can significantly impact the performance and longevity of your equipment. However, with the help of WearShield Epoxy Paste, repairing corroded pump housings is a straightforward and cost-effective solution.
By following the steps outlined above, you can restore the integrity of the pump housing, extending the life of your equipment and avoiding costly replacements or downtime.
With its excellent bonding properties and high resistance to wear and corrosion, WearShield is an invaluable tool for anyone looking to maintain and repair pumps – ensuring they continue to perform reliably for years to come.
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