Chiller Corrosion Under Insulation Case Study

Location:
Washington, NJ cosmetic packaging manufacturing plant.

Pain Point:
A water-cooled chiller critical to the facility’s process-cooling system was developing corrosion under insulation, putting several key components at risk of failure.

Plant’s Challenge:
The 90° compressor elbow, economizer, and evaporator barrel—all difficult-to-access components—showed significant corrosion from trapped condensation. Replacing these parts would be costly, require long lead times, and require shutdown for equipment removal.

Impact on Day-to-Day Operation:
Any leak or component failure would force an immediate chiller shutdown, halting the process-cooling capacity required for manufacturing. Even brief downtime could interrupt production, reduce output, and trigger costly unplanned maintenance. The plant needed a fast, in-place repair solution that would maintain reliable operation and avoid manufacturing disruption.

This manufacturing facility faced an urgent CUI problem on a water-cooled chiller. Several critical components—including a 90° compressor elbow, the economizer, and the evaporator barrel—had deteriorated from trapped condensation beneath insulation. Left unchecked, thinning metal could lead to leaks, forced shutdown, and costly production losses.

A regional HVAC service provider overseeing the site needed a specialty contractor with a track record of safe, fast, in-place composite repairs. They turned to Banks Industrial Group (BIG), known for its “secret sauce” approach to chiller CUI work: identify corrosion early and proactively restore structural integrity before leaks occur, especially on vulnerable elbows.

Why Elbows Matter

According to BIG’s technicians, “Corroded pipe elbows give customers nightmares.” These large, 3–4 ft elbows—often covered in wet, degraded insulation—tend to corrode heavily at flange joints and weld seams. Customers prefer not to remove elbows because opening the system introduces risk, added labor, and longer downtime. BIG’s ability to repair elbows fully in place eliminates these concerns.

How BIG Completed the Repair

BIG performed mechanical surface preparation, restored lost metal with Belzona 1212, and applied Belzona SuperWrap II reinforcement to the damaged elbow and economizer. Technicians emphasized that SuperWrap II can restore strength almost indefinitely when installed proactively. The evaporator barrel received a Belzona 5892 corrosion barrier coating to stop future CUI before re-insulation.

The entire project was completed in just two days, with the chiller kept under slight vacuum and remaining online throughout the repair. BIG technicians note, “We’ve never had a call-back—customers are always happy with the repair.”

Results for Contractor and Facility

No shutdown or disruption to manufacturing
Significant savings by avoiding elbow or component replacement
No hot work and minimal site intrusion
Long-term reliability and extended chiller service life
A proactive maintenance strategy contractors can offer before leaks occur

This case demonstrates how SuperWrap II composite repairs deliver fast, durable, in-place solutions that prevent failures and protect production. BIG’s precision craftsmanship and customer-focused approach help mechanical contractors offer high-value, preventive repair options without shutting down essential equipment.