Epoxy composite fillers: the ultimate solution for surface repair and restoration

When a pump casing develops a crack, a heat exchanger tube sheet starts pitting, or a shaft journal shows signs of corrosion damage, the default choice is often to replace the component.

It’s the safe call, but it’s rarely the smart choice.

Replacement typically entails long procurement lead times, extended downtime, high costs, and a significant environmental toll. SÄKAPHEN’s epoxy composite fillers offer a proven alternative: repair the component, restore its original dimensions, and return it to service, all durably and cost-effectively.

5 reasons to choose epoxy composite fillers

1. They eliminate the need to replace components
Epoxy composite fillers are engineered to restore lost material, rebuild worn surfaces, and repair voids, cracks, pitting, and other surface defects in metallic and thermoset substrates. Rather than sourcing and fitting a new part, maintenance teams can repair it in place (in the workshop or on site) and restore the component to full serviceability.

2. They’re fully machinable after cure
Once polymerized, both SÄKAPHEN epoxy composite fillers can be machined, drilled, tapped, and finished to the original tolerances. Rebuilding a shaft journal, restoring a flange face, or repairing a bearing housing is possible without compromising dimensional accuracy or surface finish.

3. They are compatible with virtually any industrial substrate
Both products adhere to carbon steel, stainless steel, aluminum, and other alloys, as well as thermoset substrates. Surface preparation to SA 2½–SA 3 and a 40–60 µm surface profile are all that’s required before application.

4. They’re compatible with a wide range of protective coating and lining systems
Repaired surfaces can be overcoated with most industrial coatings, including epoxy and even baked epoxy-phenolic and phenolic linings. This makes epoxy composite fillers an ideal preparation step before applying a high-performance protective system, ensuring a uniform substrate without compromising the final lining’s performance.

5. They’re low-VOC, ultra-high-solid products suited for both workshop and on-site work
With a solids content of 80–95% by weight, the SÄKAPHEN epoxy composite fillers minimize solvent emissions while delivering excellent film build. No specialized dispensing equipment is required, and both products can be applied on-site, reducing turnaround time and logistics complexity.

Ceramoclad 221: the high-performance product
When the repair environment is demanding (e.g. high temperatures, aggressive chemicals, or the need to overcoat with baked phenolics), Ceramoclad 221 is the solution. This two-pack, amine-cured epoxy composite filler is reinforced with ceramic and modified silicates, delivering exceptional mechanical strength during and after installation and adhesion exceeding 20 N/mm².

The standout feature is its thermal performance: Ceramoclad 221 withstands continuous dry service up to 150°C (300°F) and peak temperatures up to 220°C (430°F). This makes it suitable for components in high-temperature process environments where conventional fillers would soften or fail.
The metal-free formulation eliminates the risk of cross-contamination with metallic substrates – an important consideration when repairing equipment in contact with sensitive process fluids. Chemical resistance spans a pH range of 1–13, covering all types of water, including brackish, river, sea, and deionized.

Supplied in a dual-cartridge system compatible with standard 310 ml rod-operated or battery-powered caulking guns, Ceramoclad 221 requires no specialized mixing equipment. Chemical cure is complete in 7 days, with an overcoating window of 8–24 hours. Once cured, it can be overcoated with most baked phenolic and epoxy-phenolic linings, a capability few cold-cured fillers can match.
Typical applications include repairing pitting and cracks in casings, pipes, tanks, and process equipment, as well as patching damage on shafts and rotating components.

SÄKATONIT K 80 LS: the hydrophobic product
When the challenge is water, SÄKATONIT K 80 LS is the specialist solution. Developed specifically for tube sheet coating in power plants, water treatment facilities, desalination plants, and the chemical industry, this two-pack, cold-cured epoxy system offers a distinctive advantage: outstanding hydrophobic properties that actively resist caking, fouling, and incrustation on coated surfaces.

SÄKATONIT K 80 LS is self-priming and can be applied directly to metal. One product serves as primer, putty, and top coat, efficiently minimizing material waste and simplifying the application process. It covers a pH range of 1–13 and is resistant to all water types, including brackish, river, sea, and deionized, as well as a broad range of substances from acidic to strongly alkaline, including inorganic salts and their solutions. Temperature resistance ranges from -20°C to +90°C dry and from -20°C to +70°C wet, well suited to the operating conditions typical of heat exchanger and water treatment applications.

Surface quality is a notable differentiator: the smooth, glossy red finish achieves a surface roughness (Ra) of just 0.195 µm and a surface tension below 28 mN/m, making it highly resistant to deposit buildup.

Filling the gaps: get in touch
Surface damage doesn’t have to mean component replacement. Whether you’re dealing with pitting in pump casings, corroded tube sheets, or worn shaft journals, SÄKAPHEN’s epoxy composite fillers offer a cost-effective alternative: repairing the component, restoring its original dimensions, and returning it to service permanently.Contact SÄKAPHEN’s technical team to discuss the right product for your specific repair challenge.

FAQ
1. Can epoxy composite fillers be overcoated with heat-cured linings?
Yes, Ceramoclad 221 is formulated to be compatible with baked phenolic and epoxy-phenolic systems, making it an ideal substrate preparation material when a high-performance heat-cured lining is specified.

2. Do I need specialized equipment to apply these fillers?
No: Ceramoclad 221 is supplied in a dual-cartridge system compatible with standard caulking guns, and SÄKATONIT K 80 LS is a trowel-applied system that requires no special dispensing tools. Both products can be applied on-site without workshop infrastructure.

3. What’s the difference between Ceramoclad 221 and SÄKATONIT K 80 LS?
Ceramoclad 221 is optimized for high-temperature environments and offers broad compatibility with protective coating systems, including baked phenolics. SÄKATONIT K 80 LS is engineered for water-contact applications where hydrophobic properties, fouling resistance, and resistance to galvanic corrosion are the priorities.