Quick Pipe Repair with Devcon® in Saudi Steel Plant

Problem Overview

In a steel plant located in Saudi Arabia, a critical section of the seawater outlet system developed a serious leak at the DN600 nozzle of a return header. The leak stemmed from severe corrosion damage to the carbon steel structure, including the internal rubber lining meant to protect the pipe from saltwater exposure.

This wasn't a minor leak. The damage was too extensive for temporary patches or quick fixes. With highly corrosive saltwater running through the system as part of the cooling process, leaving the damage unaddressed would have risked further deterioration of the pipe—especially around the nozzle flange at the top of the return header.

The plant urgently needed a long-term, corrosion-resistant solution that could be applied quickly and reduce future maintenance requirements.

The Solution: Devcon® Putties to the Rescue 

To meet the dual need for speed and durability, the plant maintenance team used a combination of Devcon Plastic Steel 5 Minute® Putty (SF) and Devcon Flexane® 80 Putty.

Here’s how the repair was carried out:

Step 1: Surface Preparation

The damaged metal surface was thoroughly cleaned to remove corrosion and any contaminants. This step ensured proper adhesion and maximized the repair’s longevity.

Step 2: Rebuilding with Devcon Plastic Steel 5 Minute® Putty (SF)

This fast-curing steel-filled epoxy putty was applied to the corroded area. It set within minutes, allowing the team to rebuild the missing metal and quickly stop the leak. The putty’s high strength and chemical resistance made it ideal for restoring structural integrity under harsh seawater conditions.

Step 3: Structural Reinforcement

A carbon steel plate was bonded over the repaired section to provide mechanical support and reinforce the weakened nozzle area.

Step 4: Rubber Lining Simulation with Devcon Flexane® 80 Putty

Next, Devcon® Flexane® 80 Putty—a flexible, urethane-based putty—was applied over the repaired area. This step was critical in mimicking the original rubber lining and matching the required surface height. The Flexane putty offered excellent flexibility and chemical resistance, even in challenging geometries where traditional rubber linings often fail.

Step 5: Composite Wrap Application

To complete the repair, a composite wrap was used, bringing the entire section back to its original strength. This was done in accordance with ISO 24817 standards, which govern composite repairs on pressurized piping systems.

Results: Speed, Savings, and Strength

Rapid Repair
The full repair was completed and functional within 8 hours—meeting the plant’s strict downtime limitations. The fast cure time of the Devcon putties played a crucial role in achieving this.

Significant Cost Savings
Replacing and welding a new DN600 return nozzle header would have been time-consuming and costly, both in terms of materials and labor. By using Devcon products, the plant avoided expensive shutdowns and minimized maintenance expenditure.

Long-Term Protection
Both the Devcon Plastic Steel® 5 Minute® Putty (SF) and the Flexane® 80 Putty are known for their exceptional durability and resistance to harsh chemicals like saltwater. The seamless application of the Flexane putty also eliminated weak points typically seen in rubber linings over complex surfaces.

Conclusion: A Proven Repair Solution for Corrosive Environments

This project is a clear example of how Devcon® engineered repair solutions can effectively extend the life of industrial assets, even in highly corrosive environments. With minimal downtime, lower costs, and excellent durability, Devcon’s high-performance putties proved to be a smart alternative to pipe replacement.

Want to Learn More? 

Contact us today to discover how Devcon® solutions can help protect and repair your critical infrastructure—efficiently and reliably.